Chevrolet - Impala - Workshop Manual - 2004 - 2004

Factory Workshop Manual Make Chevrolet Model Impala Engine and year V6-3.8L VIN K (2004) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 10 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 11 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 12 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 13 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 14 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 15 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 16 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 17 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 18 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 19 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 20 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 21 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 22 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 23 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 24 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 25 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 26 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 27 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 28 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 29 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 30 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 31 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 32 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 33 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 34 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 35 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 36 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 37 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 38 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 39 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 40 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 41 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 42 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 43 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 44 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 45 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 46 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 47 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 48 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 49 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 50 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 51 Accessory Delay Module: Electrical Diagrams Retained Accessory Power (RAP) Diagram 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 52 Retained Accessory Power (RAP) Diagram 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 53 Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) Retained accessory power (RAP) is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its shut-off limit. The modules listed below all receive a RAP message from the body control module (BCM) over the serial data circuits. The BCM monitors the ignition switch position, battery condition and passenger compartment door status to determine whether RAP should be initiated. The BCM then sends a message to the listed modules telling them that they are in RAP power mode. The modules then support the operation of the systems under their control as required by their RAP power mode strategy. RAP will end when 1 of the following conditions are met: The BCM receives an input, as a hard wired input from the door switches, indicating the opening of a passenger compartment door. - The BCM receives a message from its internal timer indicating the end of the RAP period after 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. - The transition from OFF to RUN/ON or ACC of the ignition switch. The BCM then sends a serial data message to the listed devices ending the RAP function. The devices receiving serial data messages for RAP functions are: Auxiliary power drop connector - Driver information center (DIC) - Instrument panel cluster (IPC) - Radio - Remote CD player, if equipped - Vehicle interface unit (VIU), if equipped RELAY CONTROL OF RETAINED ACCESSORY POWER (RAP) RAP is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its shut-off limit. The BCM closes the RAP relay in either the RAP function as described above or if the BCM detects a RUN/ON or accessory power mode. This provides power for the following: The power windows - The sunroof control module, if equipped The BCM opens the RAP relay to end the RAP function when it ends the RAP function as outlined in the previous text. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point DIAGNOSTIC STARTING POINT - ACCESSORY DELAY MODULE Begin the system diagnosis with a Diagnostic System Check - Accessory Delay Module. The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check DIAGNOSTIC SYSTEM CHECK - ACCESSORY DELAY MODULE TEST DESCRIPTION The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. The presence of DTCs which begin with U indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. TEST Steps 1 - 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 56 Steps 4 - 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 57 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms SYMPTOMS - ACCESSORY DELAY MODULE IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory Power (RAP) Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which may affect the operation of the retained accessory power system. - Inspect the easily accessible or visible system components for obvious damage or conditions which may cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 58 Steps 1 - 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 59 Steps 10 - 11 Steps 1 - 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 60 Steps 4 - 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 61 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Software Part Number: Part number of component program or the ECU. Used to determine applicability to vehicle RPO content. Accessory Switch: Input from ignition switch Accessory circuit. Used to determine power mode. Hot in ACCESSORY and RUN. Driver Door Open Sw.: Input from the driver door indicating door status (Open-Closed). Door Ajar Switches: Input showing state of the passenger door(s). Doors Battery Fd: Indicates completion of the power circuit for the door control functions. Doors System Gnd: Indicates the completion state of the ground circuit for the door functions. Electronics Battery Fd: Data indicates the voltage detected by the control module on the power circuit for the module internal devices. Electronics Battery Fd: Input indicates the completion state of the power circuit for the module internal devices. Electronics System Gnd: Indicates the completion state of the ground circuit for the module internal devices. Ignition 0: Input to the control module from the ignition switch indicating the Ignition 0 position. Switch closed (HOT) in ignition switch positions Unlock, Accessory, Run, Crank. Ignition 1: Input to the control module from the ignition switch indicating the Ignition 1 position. Switch closed (HOT) in ignition switch positions Run, Crank. Inadvertent Power Output: Input indicating the sensed state of the inadvertent power request circuit. Inadvertent Power Relay: Output indicating the state as commanded by the control module. Lamp Request: Input telling the control module to initiate inadvertent power management. Load Management Status: Output indicating the power mode commanded. Loads Battery Fd: Indicates the completion state of the supply circuit for the high current loads. Loads System Gnd: Indicates completion state of the ground circuit for the high current loads. Pass Door Jamb Sw.: Input showing the state of the front passenger door. RAP Relay: Output indicates state that the control module has commanded. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 62 Scan Tool Data List Scan Tool Output Controls Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > Customer Interest for Antenna Control Module: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception Antenna Control Module: Customer Interest Audio System - Static/Poor Radio Reception Bulletin No.: 05-08-44-008A Date: June 17, 2005 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Static, Poor and/or No AM/FM Radio Reception In Police Package Equipped Vehicles (Replace Radio Antenna Module) Models: 2004-2005 Chevrolet Impala Built After VIN Breakpoint 49302036 with Police Package (RPO 9C1) Supercede: This bulletin is being revised to include Diagnostic and Repair Information, remove an RPO code and include a VIN breakpoint. Please discard Corporate Bulletin Number 05-08-44-008 (Section 08 - Body and Accessories). Condition Some customers may comment that certain police package vehicles equipped with radio communication equipment may experience poor AM/FM radio reception, no radio reception and/or static through the radio system. Cause Police package vehicles radio communication equipment may overload the radio AM/FM radio antenna module. Diagnosis To ensure the radio antenna module is the cause of the poor reception, refer to Radio Poor Reception (SI Document ID # 782713). Correction If diagnosis leads to a suspect radio antenna module, replace the Radio Antenna Module. Refer to Antenna Module Replacement (SI Document ID # 1515377). Dealer Action Contact customers that were told they would be notified when this repair became available. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > Customer Interest for Antenna Control Module: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception > Page 71 Parts Parts will be available for dealer ordering on June 20, 2005. Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna Control Module: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception Antenna Control Module: All Technical Service Bulletins Audio System - Static/Poor Radio Reception Bulletin No.: 05-08-44-008A Date: June 17, 2005 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Static, Poor and/or No AM/FM Radio Reception In Police Package Equipped Vehicles (Replace Radio Antenna Module) Models: 2004-2005 Chevrolet Impala Built After VIN Breakpoint 49302036 with Police Package (RPO 9C1) Supercede: This bulletin is being revised to include Diagnostic and Repair Information, remove an RPO code and include a VIN breakpoint. Please discard Corporate Bulletin Number 05-08-44-008 (Section 08 - Body and Accessories). Condition Some customers may comment that certain police package vehicles equipped with radio communication equipment may experience poor AM/FM radio reception, no radio reception and/or static through the radio system. Cause Police package vehicles radio communication equipment may overload the radio AM/FM radio antenna module. Diagnosis To ensure the radio antenna module is the cause of the poor reception, refer to Radio Poor Reception (SI Document ID # 782713). Correction If diagnosis leads to a suspect radio antenna module, replace the Radio Antenna Module. Refer to Antenna Module Replacement (SI Document ID # 1515377). Dealer Action Contact customers that were told they would be notified when this repair became available. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna Control Module: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception > Page 77 Parts Parts will be available for dealer ordering on June 20, 2005. Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > Page 78 Antenna Control Module: Locations Left Side Of Rear Window Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > Page 79 Left Side Of Rear Window Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > Page 80 Radio Antenna Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > Page 81 Antenna Control Module: Service and Repair ANTENNA MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the upper trim panel from the left rear quarter. 2. Disconnect the antenna amplifier electrical connector and the antenna coaxial cable. The antenna coaxial cable uses a sliding snap-lock. Pull the lock in order to remove the antenna coaxial cable. 3. Detach the black antenna leads from the glass. The upper lead is held to the body metal with a wiring clip. Carefully pry the clip out of the metal. 4. Remove the antenna amplifier bolt. 5. Remove the antenna amplifier. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Position the antenna amplifier to the inner upper panel of the left rear window. Install the antenna amplifier bolt. Tighten Tighten the bolt to 3 N.m (27 lb in). IMPORTANT: The antenna coaxial cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. 2. Connect the antenna amplifier electrical connectors: 2.1. Position the antenna coaxial cable behind the sliding lock feature. 2.2. Install the antenna coaxial cable to the sliding lock feature. IMPORTANT: If the wiring clip is faulty, replace the wiring clip prior to installation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > Page 82 3. Install the antenna leads to the rear window terminals. Push the wiring clip on the upper lead into the hex hole in the metal. 4. Install the upper trim panel at the left rear quarter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 91 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 92 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 93 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 04-07-30-013B > Feb > 07 > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 04-07-30-013B > Feb > 07 > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 103 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 04-07-30-013B > Feb > 07 > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 104 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > 04-07-30-013B > Feb > 07 > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 105 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > Page 106 Engine Block Heater: Service and Repair Heater Cord Coolant Heater Cord Replacement (3.8L) Removal Procedure 1. Remove the coolant heater cord retainer from the upper radiator support. 2. Raise and support the vehicle. 3. Cut the coolant heater cord retaining straps from the engine wiring harness. 4. Disconnect the coolant heater cord from the coolant heater. 5. Lower the vehicle. 6. Remove the coolant heater cord from the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Communications Control Module: > Page 107 Installation Procedure Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. 1. Install the coolant heater cord to the vehicle. 2. Raise the vehicle. 3. Connect the coolant heater cord to the coolant heater. 4. Install new retaining straps to the coolant heater cord and the engine wiring harness. 5. Lower the vehicle. 6. Install the coolant heater cord retainer to the upper radiator support. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 116 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 117 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 118 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 119 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 120 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 121 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 122 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 123 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 124 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 125 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 126 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 127 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 128 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 129 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 130 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 131 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 132 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 133 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 134 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 135 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 136 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 137 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 138 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 139 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 140 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 141 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 142 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 143 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 144 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 145 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 146 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 147 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 148 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 149 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 155 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: Customer Interest OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 160 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 165 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 170 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 171 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 177 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 186 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 187 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 188 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 189 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 190 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 191 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 192 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 193 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 194 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 195 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 196 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 197 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 198 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 199 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 200 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 201 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 202 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 203 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 204 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 205 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 206 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 207 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 208 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 209 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 210 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 211 Circuit/System Testing Component Testing Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 216 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 217 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 218 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 219 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 220 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 221 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 222 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 223 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 224 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 225 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 226 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 227 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 228 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 229 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 230 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 231 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 232 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 233 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 234 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 235 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 236 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 237 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 238 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 239 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 240 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 241 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 242 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 243 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 244 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 245 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 246 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 247 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 248 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 249 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 254 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 255 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 256 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 257 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 258 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 259 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 260 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 261 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 262 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 263 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 264 Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 265 Labor Time Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 270 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 279 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 288 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 293 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 294 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 300 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 309 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 310 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 311 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 312 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 313 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 314 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 315 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 316 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 317 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 318 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 319 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 320 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 321 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 322 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 323 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 324 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 325 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 326 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 327 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 328 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 329 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 330 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 331 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 332 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 333 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 334 Circuit/System Testing Component Testing Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 339 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 340 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 341 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 342 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 343 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 344 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 345 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 346 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 347 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 348 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 349 Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 350 Labor Time Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 355 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 364 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 373 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 378 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 379 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 389 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 390 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 391 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 392 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 393 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 394 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 395 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 396 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 397 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 398 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 399 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 400 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 401 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 402 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 403 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 404 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 405 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 406 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 407 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 408 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 409 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 410 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 411 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 412 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 413 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 414 Circuit/System Testing Component Testing Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 419 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 420 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 421 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 422 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 423 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 424 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 425 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 426 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 427 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 428 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 429 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 430 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 431 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 432 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 433 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 434 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 435 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 436 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 437 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 438 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 439 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 440 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 441 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 442 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 443 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 444 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 445 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 446 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 447 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 448 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 449 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 450 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 451 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 452 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 457 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 458 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 459 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 460 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 461 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 462 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 463 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 464 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 465 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 466 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 467 Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 468 Labor Time Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 473 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification and the 11-digit electronic serial number, are used by the National Cellular Network and OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 1. Open the rear compartment. 2. Remove the communication interface module cover. 3. Remove the bracket nuts from the communication interface module. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair > Page 485 4. Adjust the assembly for access. 5. Disconnect the cellular antenna cable from the communication interface module. 6. Disconnect the electrical connectors from the module. 7. Disconnect the GPS antenna cable from the module. 8. Remove the bolts (1) from the communication interface module. 9. Remove the communication interface module (2). INSTALLATION PROCEDURE 1. Record the 11-digit electronic serial number (ESN) and the 10-digit station identification (STID) number from the label on the new VCIM. 2. Position the communication interface module to the bracket (2). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the communication interface module bolts (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair > Page 486 Tighten Tighten the bolts to 10 N.m (89 lb in). 4. Connect the GPS antenna cable to the module. 5. Connect the electrical connectors to the module. 6. Connect the cellular antenna cable to the module. IMPORTANT: After replacing the communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. 7. Reconfigure the OnStar(R) system. Refer to OnStar Reconfiguration. 8. Position the assembly to the studs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair > Page 487 9. Install the bracket nuts to the communication interface module. Tighten Tighten the nuts to 4 N.m (35 lb in). 10. Install the communication interface module cover. 11. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 496 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 497 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 498 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 504 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 505 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 506 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Procedures Seat Heater Control Module: Procedures HEATED SEAT CONTROL MODULE REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Position the seat to the full-up position. 2. Remove the bolts that secure the front seat frame to the floor. 3. Rotate the seat forward to access the heater module. 4. Disconnect the seat electrical harness connector. 5. Disconnect the heater control module from the seat frame by sliding the control module toward the front of the seat. 6. Disconnect the electric harness connector (1) from the heater module (2). 7. Remove the heater module from the front seat. INSTALLATION PROCEDURE 1. Position the heater module to the front seat. 2. Connect the electrical harness connector (1) to the heater module (2). 3. Position the module on the frame and slide the module rearward until the module locks into place. 4. Lower the seat. 5. Connect the seat electrical harness connector. NOTE: Refer to Fastener Notice in Service Precautions. 6. Install the bolts that secure the front bucket seat adjuster to the floor pan. Tighten Tighten the bolts to 42 N.m (31 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Procedures > Page 512 7. Reposition the front seat to the original position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Procedures > Page 513 Seat Heater Control Module: Removal and Replacement Heated Seat Control Module Replacement - Front Removal Procedure 1. Position the seat to the full-up position. 2. Remove the bolts that secure the front seat frame to the floor. 3. Rotate the seat forward to access the heater module. 4. Disconnect the seat electrical harness connector. 5. Disconnect the heater control module from the seat frame by sliding the control module toward the front of the seat. 6. Disconnect the electrical harness connector (1) from the heater module (2). 7. Remove the heater module from the front seat. Installation Procedure 1. Position the heater module to the front seat. 2. Connect the electrical harness connector (1) to the heater module (2). 3. Position the module on the frame and slide the module rearward until the module locks into place. 4. Lower the seat. 5. Connect the seat electrical harness connector. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bolts that secure the front bucket seat adjuster to the floor pan. Tighten the bolts to 42 N.m (31 lb ft). 7. Reposition the front seat to the original position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Diagrams Seat Heater Relay: Diagrams Heated Seat Relay-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Diagrams > Page 517 Heated Seat Relay-Front Passenger Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof / Moonroof Module: Diagrams Sunroof Module, C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Page 521 Sunroof Module, C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Page 522 Sunroof / Moonroof Module: Service and Repair SUNROOF CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the headliner. 2. Remove the nylon tie straps located from both ends of the sunroof control module (2). 3. Release the control module retainers from the metal bracket by sliding the control module toward the left side of the vehicle. 4. Remove the control module from the sunroof module. 5. Disconnect the electrical connectors from the control module. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Page 523 6. Remove the control module from the vehicle. INSTALLATION PROCEDURE 1. Position the control module to the sunroof module. 2. Connect the electrical connectors to the ends of the control module. 3. Install the control module to the sunroof module by sliding it to the right to engage the retainers. 4. Install the nylon tie straps at both ends of the control module (2). 5. Check the operation of the sunroof module. 6. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 528 Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 529 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Notice: To prevent equipment damage, never connect or disconnect the wiring harness connection from the EBCM with the ignition switch in the ON position. 1. Turn the ignition switch to the OFF position. 2. Remove the fuel injector sight shield, 3.8 L engine only. 3. Remove the front fender upper diagonal brace. 4. Disconnect the accelerator and cruise control cable from the accelerator control cable bracket. 5. Disconnect the cruise control module from the left strut tower. It is not necessary to remove the cable from the module. Position the module and cables aside. 6. Remove the air cleaner intake duct. 7. Disengage the red locking tab (1) from connector lock tab. 8. Push down lock tab and then move sliding connector cover (2) to the open position. 9. Disconnect the EBCM harness connector. 10. Remove any dirt/debris from the assembly. 11. Remove the four EBCM to BPMV retainers. Important: Do not pry apart using a tool. Be careful not to damage BPMV surface. Important: Care must be taken not to damage the solenoid valves when the EBCM is removed from the BPMV. 12. Separate the EBCM from the BPMV by gently pulling apart until separated. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 530 1. Install the EBCM to the BPMV. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four retainers that attach the EBCM to BPMV. ^ Tighten the retainers to 5 Nm (44 inch lbs.). 3. Connect the EBCM harness connector. 4. Push down lock tab (1) and then move sliding connector cover (2) back in the home position to lock. 5. Reengage the red locking tab (1) to the connected lock tab. 6. Install the air cleaner intake duct. 7. Reposition the module and cables. Connect the cruise control module to the left strut tower. 8. Connect the accelerator and cruise control cable to the accelerator control cable bracket. 9. Install the front fender upper diagonal brace. 10. Install the fuel injector sight shield, 3.8 L engine only. 11. Turn the ignition switch to the RUN position, do not start engine. 12. Perform the Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 535 Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 536 Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 537 Cruise Control Module (CCM) Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 538 Cruise Control Module: Service and Repair CRUISE CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE The cruise control module is mounted to the left strut tower and must be serviced as a complete unit. 1. Remove the cruise control cable from the cruise control module. 2. Disconnect the cruise control module electrical connector. 3. Remove the cruise control module shock tower nuts. 4. Remove the cruise control module. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 539 1. Install the cruise control module on the mounting studs located on the shock tower. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the cruise control module mounting nuts. Tighten Tighten the cruise control module to shock tower nuts to 2 N.m (18 lb in). 3. Connect the cruise control module electrical connector. IMPORTANT: The cruise control cable does not require mechanical adjusting after the replacement. The cruise control module internally adjusts the cable. 4. Install the cruise control cable to the cruise control module. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Remove the underhood lower relay cover. 3. Remove the A/C compressor control relay from the electrical center. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Service and Repair > Page 544 1. Install the A/C compressor control relay into the electrical center. 2. Install the underhood lower relay cover. 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations Middle Center Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 548 Control Module HVAC: Diagrams HVAC Control Module Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 549 HVAC Control Module Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 550 HVAC Control Module Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 551 Control Module HVAC: Description and Operation HVAC CONTROL MODULE The HVAC control module is a Class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The control module supports the following features: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 552 Control Module HVAC: Service and Repair BLOWER CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the right side instrument panel insulator. 2. Disconnect the electrical connector from the blower control module. 3. Remove the two heat stakes from the blower control module using a small chisel. 4. Remove the blower control module. INSTALLATION PROCEDURE 1. Install the blower control module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the two new screws in the pre drilled holes to the side of the heat stakes in the blower control module and HVAC module assembly. Tighten Tighten the screws to 1.5 N.m (13 lb in). 3. Connect the electrical connector to the blower control module. 4. Install the right side instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service and Repair > Procedures Audible Warning Device Control Module: Procedures MULTIFUNCTION ALARM MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster trim panel. 2. Remove the screws from the radio delete plate. 3. Remove the radio delete plate from the instrument panel. 4. Disconnect the electrical connector from the multifunction alarm module. 5. Remove the multifunction alarm module from the instrument panel by lifting up and out. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service and Repair > Procedures > Page 558 1. Install the multifunction alarm module to the instrument panel by pressing in place until fully seated. 2. Connect the electrical connector to the multifunction alarm module. 3. Install the radio delete plate to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the radio delete plate. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the instrument cluster trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service and Repair > Procedures > Page 559 Audible Warning Device Control Module: Removal and Replacement Multifunction Alarm Module Replacement Removal Procedure 1. Remove the instrument cluster trim panel. 2. Remove the screws from the radio delete plate. 3. Remove the radio delete plate from the instrument panel. 4. Disconnect the electrical connector from the multifunction alarm module. 5. Remove the multifunction alarm module from the instrument panel by lifting up and out. Installation Procedure 1. Install the multifunction alarm module to the instrument panel by pressing in place until fully seated. 2. Connect the electrical connector to the multifunction alarm module. 3. Install the radio delete plate to the instrument panel. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the radio delete plate. Tighten the screws to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service and Repair > Procedures > Page 560 5. Install the instrument cluster trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Diagrams Emergency Vehicle Rear Compartment Lid Lamps Relay Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Located in Junction Block- Left I/P Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block Relay Box: Locations Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 573 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 574 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 575 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 576 Relay Box: Locations Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 577 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 578 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 579 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 580 Relay Box: Locations Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 581 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 582 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 583 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 584 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 585 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 586 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 587 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 588 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 589 Relay Box: Locations Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 590 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 591 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 592 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 593 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 594 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 595 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 596 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 597 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block Relay Box: Application and ID Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 600 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 601 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 602 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 603 Relay Box: Application and ID Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 604 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 605 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 606 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 607 Relay Box: Application and ID Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 608 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 609 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 610 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 611 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 612 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 613 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 614 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 615 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 616 Relay Box: Application and ID Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 617 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 618 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 619 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 620 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 621 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 622 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 623 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 624 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the positive battery cables from the underhood fuse block terminals. 3. Remove the tape from the wiring harness at the base of the underhood fuse block base. 4. Release the underhood fuse block(s) clip retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 627 5. Remove the fuse block(s) and wiring harness lifting up from the base and reposition from the base. 6. Remove the nuts from the underhood fuse block base. 7. Remove the underhood fuse block base from the shock tower. 8. Remove the underhood fuse block lower front terminal positive assurance retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 628 9. Remove the plastic shields from the battery cable and buss bar terminals, using a small flat-bladed tool to release the clip retainer. 10. Remove the bolts from the buss bar jumper bar. 11. Remove the buss bar jumper bar from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 629 12. Remove the fuses from the fuse block(s) to access the buss bar terminal release tabs. 13. Remove the buss bar(s) from the fuse block(s) using a terminal releasing tool, and pulling down and out on the buss bar. 14. Remove the buss bar(s) from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 630 15. Release the clip retainers from the underhood fuse block(s) battery cable and buss bar terminals using a small flat-bladed tool. 16. Remove the underhood fuse block(s) battery cable and buss bar terminals from the fuse block by pulling down. 17. Remove the fuse block and lamp wiring harness from the vehicle, if required. INSTALLATION PROCEDURE 1. Install the underhood fuse block(s) battery cable and buss bar terminals to the fuse block(s) by sliding up into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 631 2. Install the buss bar(s) to the fuse block(s) pressing into place until fully seated. 3. Position the underhood fuse block terminal positive assurance retainers to the fuse block(s). 4. Install the underhood fuse block(s) terminal positive assurance retainers pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 632 5. Install the fuses to the fuse block(s) that were removed to access the buss bar terminal release tabs. 6. Install the buss bar jumper bar to the fuse block(s). NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the bolts to the buss bar jumper bar. Tighten Tighten the jumper bar bolts to 9 N.m (80 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 633 8. Install the plastic shields to the battery cable and buss bar terminals pressing into place until fully seated. 9. Position the underhood fuse block(s) to the underhood fuse block base retaining locks. 10. Install the underhood fuse block(s) into the underhood fuse block base retaining locks pressing in until fully seated. 11. Install new tape to the wiring harness at the base of the underhood fuse block base. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 634 12. Position the underhood fuse block base to the shock tower. 13. Install the nuts to the underhood fuse block base. Tighten Tighten the fuse block base nuts to 9 N.m (80 lb in). 14. Install the positive battery cables to the underhood fuse block. Tighten Tighten the positive battery cables nuts to 15 N.m (11 lb ft). 15. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 635 Relay Box: Service and Repair Instrument Panel Electrical Center / Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left I/P fuse block access hole cover. 3. Disconnect the outboard wiring harness connector C2 from the junction block. 4. Remove the connector position assurance (CPA) from the yellow inflatable restraint connector. Disconnect and reposition the yellow inflatable restraint connector for access to the bolts. 5. Remove the steering column filler. 6. Remove the I/P driver knee bolster. 7. Disconnect the inner wiring harness connector from the junction block. 8. Remove the junction block bolts. 9. Remove the junction block tab from the slot in the cross vehicle beam. Pull the junction block away from the I/P. 10. Remove the junction block. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 636 1. Install the junction block tab to the slot in the cross vehicle beam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the junction block bolts. Tighten Tighten the junction block bolts to 10 N.m (89 lb in). 3. Connect the inner wiring harness connector to the junction block. Tighten Tighten the inner wiring harness connector bolt to 7 N.m (62 lb in). 4. Install the I/P driver knee bolster. 5. Install the steering column filler. 6. Connect the yellow inflatable restraint connector. Install the CPA. Attach the connector to the junction block. 7. Connect the outboard wiring harness connector C2 to the junction block. Tighten Tighten the body wiring harness connector bolt to 7 N.m (62 lb in). 8. Install the left I/P fuse block access hole cover. 9. Connect the negative battery cable. Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 637 REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the RH instrument panel (IP) fuse block access opening cover. 3. Disconnect the body wiring harness from the junction block. 4. Open the IP compartment. Access the junction block bolt through the open IP compartment. Remove the junction block bolt. 5. Disengage the junction block tabs from the passenger knee bolster. Pull the junction block away from the IP. 6. Disconnect the wiring harnesses from the junction block. 7. Remove the junction block. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 638 1. Connect the body wiring harnesses to the junction block. Tighten Tighten the body wiring harness connector bolts to 7 N.m (62 lb in). 2. Install the junction block tabs to the passenger knee bolster. 3. Install the junction block bolt. Tighten Tighten the junction block bolt to 10 N.m (89 lb in). 4. Close the IP compartment. 5. Connect the body wiring harness to the junction block. 6. Install the RH IP fuse block access opening cover. 7. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 639 Relay Box: Service and Repair Junction Block Replacement - Accessory Wiring JUNCTION BLOCK REPLACEMENT - ACCESSORY WIRING REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left instrument panel (I/P) insulator. 3. Remove the screws from the accessory wiring junction block. 4. Adjust the junction block for access. 5. Remove the circuit breakers (4) and the relays from the junction block as required. 6. If necessary remove the junction block from the bracket assembly. INSTALLATION PROCEDURE 1. If necessary install the junction block to the bracket assembly. 2. Install the circuit breakers (4) and the relays to the junction block as required. 3. Position the junction block to the I/P carrier. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the junction block screws. Tighten Tighten the screws to 10 N.m (89 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 640 5. Install the left I/P insulator. 6. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: Customer Interest BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 651 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: All Technical Service Bulletins BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 657 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 667 Behind Left Side Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 Body Control Module: Diagrams Body Control Module (BCM) C1 Body Control Module, C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 670 Body Control Module, C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 671 Body Control Module, C1 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 672 Body Control Module: Diagrams Body Control Module (BCM) C2 Body Control Module, C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 673 Body Control Module, C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 674 Body Control Module: Diagrams Body Control Module (BCM) C3 Body Control Module, C3 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 675 Body Control Module, C3 Part 2 Body Control Module, C3 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 676 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. The BCM has five basic modes (disarmed, standby, delayed, armed, and alarm) for operating the CTD system. The different modes are described below. 1. The BCM has the CTD system in a disarmed mode until the following conditions are detected: - Ignition key turned to the OFF position. - Any door open. - Doors locked by either the power door lock switch or the LOCK button on the transmitter. 2. The BCM enters the standby mode when the above conditions are detected. In standby mode, the BCM commands the SECURITY indicator to flash. If all the doors are closed and the LOCK button on the transmitter is used, the BCM enters the delayed mode. 3. When the last door is closed, the BCM enters the delayed mode for 30 seconds. In delayed mode the BCM commands the SECURITY indicator to illuminate ON steady. 4. After 30 seconds, the BCM enters the armed mode. Any forced entry activates the alarm mode. 5. When the BCM detects a forced entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active.The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. The body control module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(TM) data from the Passlock(TM) sensor. If the Passlock(TM) data is correct, the BCM will send a class 2 message to the PCM to enable the fuel injectors and crank relay. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(TM) data, the VTD system will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors and crank relay for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(TM) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable and crank relay enable signal to the PCM. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION During body control module (BCM) related service, the procedures below are designated to set-up the BCM correctly. Before you start, read these procedures carefully and completely. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: The BCM will not function properly if the Setup New BCM procedure is not performed. - Make sure the battery is fully charged before performing the setup procedure. - Make sure all disconnected devices and connectors have been reconnected - Perform the Theft Deterrent Re-learn procedure after successfully finishing the Setup New BCM procedure. Refer to Programming Theft Deterrent System Components in Theft Deterrent. If the Theft Deterrent Re-learn procedure is not performed after a BCM replacement, the following conditions may occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. 1. Connect a scan tool to the data link connector (DLC). 2. Turn the ignition switch ON. 3. Select Diagnostics and input all of the required data when prompted by the scan tool. 4. Select BODY CONTROL MODULE. 5. Select SPECIAL FUNCTIONS. 6. Select New VIN and input all required data. 7. Exit back to the SPECIAL FUNCTIONS menu. 8. Select BCM REPROGRAMMING. 9. The scan tool will display DO YOU WANT TO SETUP A BODY CONTROL MODULE? At the prompt, select SETUP BCM hotspot on the scan tool. 10. The scan tool will display: NOW SETTING UP THE NEW BODY CONTROL MODULE. 11. When the BCM has been setup successfully, the scan tool will display: BODY CONTROL MODULE SETUP IS COMPLETE. 12. Exit back to the SPECIAL FUNCTIONS menu. 13. Select Point of Sale in this menu. 14. Input all of the required data when prompted by the scan tool. 15. Exit back to the SET OPTIONS menu. 16. Select Option Configuration. 17. Input all of the required data when prompted by the scan tool. 18. When the BCM, VIN, Point of Sale and Option Configuration have been entered, proceed with the Theft Deterrent Re-learn procedure. 19. If the scan tool displays UNABLE TO PROGRAM BCM. BCM IS SECURED, then the BCM must be replaced and this procedure must be repeated on a new BCM. NOTE: After the above procedure has been completed, personalization of the BCM defaults to a default setting. Inform the customer that the personalization settings must be set again. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 679 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: You must perform the new body control module (BCM) setup when replacing the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 1. Disconnect the battery ground (negative) cable. 2. Remove the left instrument panel insulator. 3. Disconnect the BCM electrical connectors (2,3,4). 4. Remove the BCM (1). INSTALLATION PROCEDURE 1. Install the body control module (BCM) (1). 2. Connect the BCM electrical connectors (2,3,4). 3. Install the left instrument panel insulator. 4. Connect the battery ground (negative) cable. 5. Perform the new BCM setup. Refer to Body Control Module (BCM) Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 684 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 685 Left Front Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 Engine Control Module: Diagrams Powertrain Control Module, C1 Powertrain Control Module, C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 688 Powertrain Control Module, C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 689 Powertrain Control Module, C1 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 690 Powertrain Control Module, C1 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 691 Engine Control Module: Diagrams Powertrain Control Module, C2 Powertrain Control Module, C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 692 Powertrain Control Module, C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 693 Powertrain Control Module, C2 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 694 Powertrain Control Module, C2 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module Engine Control Module: Description and Operation Powertrain Control Module POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION The PCM communicates with the BCM over the Class 2 serial data line. When the BCM determines an incorrect password, it sends a Class 2 serial data password to the PCM in order to disable the crank relay and fuel injection system. If the BCM receives the expected voltage from the Passlock(TM) sensor, the BCM sends a class 2 serial data password to the PCM in order to enable the crank relay and fuel injection system. The PCM then allows the vehicle to start normally. POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module > Page 697 The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the PCM, allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e. misfire). WARM-UP CYCLE The PCM uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160 °F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The PCM is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module > Page 698 Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the MIL or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. The last test may have run during a previous ignition cycle if an A or B type DTC is displayed. For type C DTCs, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MIL Request: Indicates that this DTC is currently requesting the MIL. This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History: Indicates that the DTC is stored in the PCM History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear): DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module > Page 699 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM maintains proper spark and fuel injection timing for all driving conditions. Ignition control (IC) spark timing is the method the PCM uses to control spark advance. To provide optimum driveability and emissions, the PCM monitors input signals from the following components to calculate ignition spark timing: The ignition control module (ICM) - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) The following describes the PCM to ICM circuits: Low resolution engine speed signal-3 X reference-PCM input-from the ICM. The 3X reference signal is produced by the ICM. The PCM uses this signal to calculate engine RPM and crankshaft position above 1,200 RPM. The PCM also uses the pulses on this circuit to initiate fuel injector operation. The PCM compares the number of 3X pulses to the number of 18X and cam pulses. If the number of 3X pulses are incorrect while the engine is cranking or running, the PCM will set a DTC. The engine will continue to start and run normally using the 18X reference signal. - Medium resolution engine speed signal-18 X reference-PCM input-from the ICM. The 18 X reference signal is used to accurately control spark timing at low RPM and allow ignition control (IC) operation during cranking. The ICM calculates the 18X reference signal by filtering the CKP sensor 18X pulses when the engine is running and the CKP sync pulses are being received. Below 1,200 RPM, the PCM is monitoring the 18X reference signal and using the 18X signal as the reference for ignition timing advance. The PCM compares the number of 18X pulses to the number of 3X and cam pulses. If the number of 18X pulses are incorrect while the engine is cranking or running, the PCM will set a DTC. The engine will continue to start and run normally using the 3X reference signal. - Camshaft position-PCM input-from the ICM. The PCM uses this signal to determine the position of the cylinder #1 piston during the pistons power stroke. This signal is used by the PCM to calculate true sequential fuel injection (SFI) mode of operation. The PCM compares the number of CAM pulses to the number of 18 X and 3 X reference pulses. If the number of 18 X and 3 X reference pulses occurring between CAM pulses is incorrect, or if no CAM pulses are received while the engine is running, the PCM will set a DTC. If the CAM signal is lost while the engine is running the fuel injection system will shift to a calculated sequential fuel injection mode based on the last CAM pulse, and the engine will continue to run. The engine can be re-started and will run in the calculated sequential mode as long as the condition is present with a 1 in 6 chance of being correct. - Low reference-PCM input-this is a ground circuit for the digital RPM counter inside the PCM, but the wire is connected to engine ground only through the ICM. This circuit assures there is no ground drop between the PCM and ICM. - IC timing signal-PCM output-to the ICM. The ICM controls spark timing while the engine is cranking, this is called bypass mode. Once the PCM receives 3 X reference signals from the ICM, the PCM applies 5 volts to the IC timing signal circuit allowing the ICM to switch spark advance to PCM control. - IC timing control-PCM output-to the ICM. The IC output circuitry of the PCM sends out timing signals to the ICM on this circuit. When in the Bypass Mode, the ICM grounds these signals. When in the IC Mode, the signals are sent to the ICM to control spark timing. - Default mode due to a system failure The other mode is the IC mode during which the PCM is receiving the 18X and the 3X reference pulses from the CKP sensor and is supplying 5 volts to the IC timing signal circuit. This allow the PCM to accurately control spark timing for all driving conditions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 700 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for PCM replacement, inspect the PCM first to see if the replacement is the correct part. If the PCM is faulty, remove the PCM and install the new service PCM. The new service PCM will not be programmed. You must program the new PCM. DTC P0602 indicates the EEPROM is not programmed or has malfunctioned. NOTE: - Do not touch the connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage to the PCM. - Turn the ignition OFF when installing or removing the PCM connectors and disconnecting or reconnecting the power to the PCM (battery cable, PCM pigtail, PCM fuse, jumper cables, etc.) in order to prevent internal PCM damage. Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the left front inner fender brace. 3. Remove the air cleaner intake duct. 4. Remove the air cleaner housing cover screws (2). 5. Remove the air cleaner housing cover (1). 6. Without disconnecting the PCM electrical connectors, remove the PCM and the wiring harness from the air cleaner housing assembly (3). 7. Disconnect the PCM electrical connectors and remove the PCM. Installation Procedure NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the PCM to the PCM electrical connectors. Tighten Tighten the connectors to 8 N.m (71 lb in). 2. Install the PCM and the wiring harness to the air cleaner housing assembly (3). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 701 3. Install the air cleaner housing cover (1). 4. Install the air cleaner housing cover screws (2). Tighten Tighten the screws to 4 N.m (35 lb in). 5. Install the air cleaner intake duct. 6. Install the left front inner fender brace. 7. Connect the negative battery cable. 8. The new PCM must be programmed. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 706 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 707 Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 708 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 709 Right Side Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 710 Ignition Control Module: Diagrams Ignition Control Module (ICM) Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 711 Ignition Control Module (ICM) Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 712 Ignition Control Module: Description and Operation IGNITION CONTROL MODULE (ICM) AND IGNITION COILS Three dual tower ignition coils are mounted to the ICM, and are serviced individually. The ICM performs the following functions: - The ICM supplies a power and low reference circuit to the CMP and CKP sensors. - The ICM determines the correct direction of the crankshaft rotation, and cuts spark and fuel delivery to prevent damage from backfiring if reverse rotation is detected. - The ICM determines the correct coil triggering sequence, based on how many 18 X ON-OFF pulses occur during a sync pulse. This coil sequencing occurs at start-up, and is remembered by the ICM. After the engine is running, the ICM will continue to trigger the coils without the CKP sync pulse. - The ICM inputs 18 X and 3 X reference signals to the PCM. - The 3 X reference signal is also known as the low resolution engine speed signal. This signal is generated by the ICM using an internal divide-by-six circuit. This circuit divides the 18 X signal pulses by 6. This divider circuit will not begin operation without a sync pulse present at start-up, and without 18 X and 3 X reference signals no fuel injection will occur. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 713 Ignition Control Module: Service and Repair IGNITION CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the 14-way electrical connector from the ignition control module (ICM). 3. Disconnect the spark plug wires from the coil assemblies. Before removing the wires, note the position of the wires. 4. Remove the ignition coil screws (1). 5. Remove the ignition coils (2) from the ICM (3). 6. Remove the ignition control module (3) from the bracket. INSTALLATION PROCEDURE 1. Install the ignition control module to the bracket. 2. Install the ignition coils (2) to the ignition control module (3). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the ignition coil screws (1). Tighten Tighten the screws to 4.5 N.m (40 lb in). 4. Connect the spark plug wires. 5. Connect the 14-way electrical connector to the module. Tighten Tighten the screw to 2.1 N.m (19 lb in). 6. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The ignition relay is a normally open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the run or start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by the relay coil, overcomes the spring tension and moves the armature allowing the relay contact to close. The closed relay contacts allow current to flow from the battery to the following fuses: Eng Devices - Oxy Sensors - DFI/MDL - Trans Sol - A/C Relay fuse - Fuel Inj When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the ignition relay fails to close, the engine will crank, but will not run. The class 2 communications will be available with the use of a scan tool. The ignition relay table assumes that the vehicle battery is fully charged. Refer to Battery Inspection/Test in Starting and Charging. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test TEST Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 717 Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 718 Steps 4-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 719 Step 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 720 Steps 7-9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 721 Steps 10-13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 722 Steps 14-16 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 723 Steps 17-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 724 Steps 21-22 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 725 Steps 23-25 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 726 Steps 26-34 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations SIR Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 731 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 732 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 733 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 734 Inflatable Restraint Sensing And Diagnostic Module: Service Precautions CAUTION: - Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 735 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The inflatable restraint sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with external sensors, if equipped, mounted at various locations, depending on vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors, if equipped. The SDM compares the result of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the deployment loops, deploying the inflator modules. The SDM records the SIR system status when a deployment occurs and commands the IPC to turn the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will turn the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 36 volt loop reserve (36 VLR) for deployment of the inflator modules. It is important to note, when disabling the SIR system for service or rescue operations, to allow the 36 VLR to dissipate, which could take up to 1 minute. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) Inflatable Restraint Sensing And Diagnostic Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module (AJ7) REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 9. CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. - Refer to SIR Caution in Service Precautions. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer. Roll back the carpet. 4. Remove the connector position assurance (CPA) from the 8-way wiring harness connector on the sensing and diagnostic module (SDM). 5. Disconnect the 8-way wiring harness connector from the SDM. 6. Remove the CPA from the 18-way wiring harness connector (2). 7. Disconnect the 18-way wiring harness connector from the SDM. 8. Remove the SDM mounting fasteners (3). 9. Remove the SDM (1) from the floor pan (2). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 738 2. Install the SDM (1) horizontally to the floor pan (2). 3. Point the arrow on the SDM toward the front of the vehicle. 4. Install the SDM mounting fasteners (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fasteners to 10 N.m (89 lb in). 5. Install the 18-way wiring harness connector to the SDM. 6. Install the CPA to the 18-way wiring harness connector. 7. Install the 8-way wiring harness connector to the SDM. 8. Install the CPA to the 8-way wiring harness connector. 9. Install the carpet and the passenger front carpet retainer. 10. Install the passenger front seat. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 9. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 739 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module (AK5) REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 9. CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. - Refer to SIR Caution in Service Precautions. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer. Roll back the carpet. 4. Remove the connector position assurance (CPA) from the wiring harness connector of the sensing and diagnostic module (SDM). 5. Disconnect the wiring harness connector from the SDM. 6. Remove the SDM mounting fasteners (3). 7. Remove the SDM (1) from the floor pan (2). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 740 2. Install the SDM (1) horizontally to the floor pan (2). 3. Point the arrow on the SDM toward the front of the vehicle. 4. Install the SDM mounting fasteners (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fasteners to 10 N.m (89 lb in). 5. Install the wiring harness connector to the SDM. 6. Install the CPA to the SDM wiring harness connector. 7. Install the carpet and the passenger front carpet retainer. 8. Install the passenger front seat. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 9. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Forward Of Windshield Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 755 Windshield Wiper System Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 756 Wiper Control Module: Service and Repair WIPER DRIVE SYSTEM MODULE REPLACEMENT TOOLS REQUIRED - J 39232 Wiper Transmission Separator - J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the air inlet grille panel. 2. Remove the wiper motor water deflector. 3. Using the J 39232 , disconnect the wiper transmission from the wiper motor crank arm to aid in the removal of the wiper drive system module. 4. Remove the wiper drive system module screws. 5. Disconnect the wiper motor electrical connector. 6. Remove the wiper drive system module from the vehicle. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 757 1. Position the wiper drive system module to the vehicle. 2. Connect the wiper motor electrical connector. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the wiper drive system screws. Tighten Tighten the screws to 10 N.m (89 lb in). 4. Using the J 39529 , Install the wiper transmission to the wiper motor crank arm. 5. Install the wiper motor water deflector. 6. Install the air inlet grille panel. 7. Inspect the wipers for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams Passlock Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Page 763 Lock Cylinder Switch: Description and Operation PASSLOCK(TM) SENSOR The Passlock(TM) sensor contains 2 hall effect sensors. The tamper hall effect sensor is on the top. The security hall effect sensor is under the tamper hall effect sensor. Both of the hall effect sensors monitor the magnet of the lock cylinder through an opening. The tamper hall effect sensor is physically placed on top of the security hall effect sensor. This arrangement enables the tamper hall effect sensor to engage first if an intruder attempts to bypass the Passlock(TM) sensor by placing a large magnet around that area of the steering column. There is a tamper resistor inside the Passlock(TM) sensor in order to help prevent tamper to the system. Passlock(TM) equipped vehicles have a selection of 10 different security resistors ranging from 0.5K ohms up to 13.6K ohms. Installing one of the security resistors inside the Passlock(TM) sensor will generate a unique Passlock(TM) code. All 10 combinations of the Passlock(TM) sensor have the same part number. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Diagrams Door Lock Cylinder Switch: Diagrams Door Lock Cylinder Switch-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Diagrams > Page 772 Door Lock Cylinder Switch-Front Passenger (If Equipped) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Front Door Trim-Typical Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 776 Power Door Lock Switch: Diagrams Door Lock Switch-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 777 Door Lock Switch-Front Passenger Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 778 Power Door Lock Switch: Description and Operation POWER DOOR LOCK SWITCHES The power door lock switches are used to either arm or disarm the CTD system. Pressing the lock position will cause the CTD to arm after all doors are closed and the 30 second delay period has elapsed. Pressing the unlock position will disarm the CTD system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 779 Power Door Lock Switch: Service and Repair POWER DOOR LOCK SWITCH REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Remove the inside door handle bezel. 2. Remove the power door lock switch from the inside door handle bezel using a small, flat-bladed tool in order to release the retainers. 3. Disconnect the electrical connector from the power door lock switch. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 780 1. Install the power door lock switch to the inside door handle bezel pressing into place until fully seated. 2. Connect the electrical connector to the power door lock switch. 3. Install the inside door handle bezel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Front Of Driver Door Trim (Mirrors) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 784 Power Mirror Switch: Diagrams Outside Rearview Mirror Switch Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 785 Outside Rearview Mirror Switch Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Procedures Power Mirror Switch: Procedures POWER MIRROR SWITCH REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Remove the front door pull cup from the front door inner trim panel. 2. Disconnect the electrical connectors from the power mirror switch. 3. Remove the power mirror switch from the front door pull cup, using a small flat-bladed tool at the side of the mirror switch in order to release the mirror control switch retainer. 4. Remove the power mirror switch from the front door pull cup. INSTALLATION PROCEDURE 1. Install the power mirror switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the power mirror switch. 3. Install the front door pull cup to the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Procedures > Page 788 Power Mirror Switch: Removal and Replacement Power Mirror Switch Replacement (Impala) Removal Procedure 1. Remove the front door pull cup from the front door inner trim panel. 2. Disconnect the electrical connectors from the power mirror switch. 3. Remove the power mirror switch from the front door pull cup, using a small flat-bladed tool at the side of the mirror switch in order to release the mirror control switch retainer. 4. Remove the power mirror switch from the front door pull cup. Installation Procedure 1. Install the power mirror switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the power mirror switch. 3. Install the front door pull cup to the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Power Seat Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 792 Power Seat Switch: Diagrams Seat Adjuster Switch-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 793 Seat Adjuster Switch-Front Passenger Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 794 Seat Adjuster Switch-Front Passenger Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures Power Seat Switch: Procedures Lumbar Switch Replacement LUMBAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the outer seat cushion trim panel. 2. Remove the screws from the lumbar control switch. 3. Remove the lumbar control switch from the outer seat cushion trim panel. INSTALLATION PROCEDURE 1. Position the lumbar control switch to the outer seat cushion trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws (1) to the lumbar control switch. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the outer seat cushion trim panel. Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE 1. Remove the front seat cushion outer trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 797 2. Remove the power front seat switch from the front seat outer trim panel, using a small flat bladed tool. 3. Disconnect the electrical connector from the power front seat switch. 4. Remove the power front seat switch from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power front seat switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 798 2. Install the power front seat switch to the front seat outer trim panel, pressing into place until fully seated. 3. Install the front seat cushion outer trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 799 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Seat Switch Replacement - Power Removal Procedure 1. Remove the front seat cushion outer trim panel. 2. Remove the power front seat switch from the front seat outer trim panel, using a small flat bladed tool. 3. Disconnect the electrical connector from the power front seat switch. 4. Remove the power front seat switch from the vehicle. Installation Procedure 1. Connect the electrical connector to the power front seat switch. 2. Install the power front seat switch to the front seat outer trim panel, pressing into place until fully seated. 3. Install the front seat cushion outer trim panel. Lumbar Switch Replacement Lumbar Switch Replacement Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 800 Removal Procedure 1. Remove the outer seat cushion trim panel. 2. Remove the screws from the lumbar control switch. 3. Remove the lumbar control switch from the outer seat cushion trim panel. Installation Procedure 1. Position the lumbar control switch to the outer seat cushion trim panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws (1) to the lumbar control switch. Tighten the screws to 2 N.m (18 lb in). 3. Install the outer seat cushion trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations Inside Rear Compartment Lid Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 804 Rear Compartment Lid Ajar Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Power Seat Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 808 Seat Heater Switch: Diagrams Heated Seat Switch-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 809 Heated Seat Switch-Front Passenger Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Procedures Seat Heater Switch: Procedures HEATED SEAT SWITCH REPLACEMENT - FRONT (IMPALA) REMOVAL PROCEDURE 1. Remove the front seat cushion outer trim panel. 2. Disconnect the electrical connector from the front seat wiring harness. 3. Remove the front seat heated seat switch, using a small, flat-bladed tool to release the retainer clips. 4. Remove the front seat heated seat switch from the front seat cushion outer trim panel. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Procedures > Page 812 1. Install the front seat heated seat switch to the front seat cushion outer trim panel, pressing into place until fully seated. 2. Connect the electrical connector to the front seat wiring harness. 3. Install the front seat cushion outer trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Procedures > Page 813 Seat Heater Switch: Removal and Replacement Heated Seat Switch Replacement - Front (Impala) Removal Procedure 1. Remove the front seat cushion outer trim panel. 2. Disconnect the electrical connector from the front seat wiring harness. 3. Remove the front seat heated seat switch, using a small, flat-bladed tool to release the retainer clips. 4. Remove the front seat heated seat switch from the front seat cushion outer trim panel. Installation Procedure 1. Install the front seat heated seat switch to the front seat cushion outer trim panel, pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Procedures > Page 814 2. Connect the electrical connector to the front seat wiring harness. 3. Install the front seat cushion outer trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Sunroof Switch (Without RPO Code U68) Sunroof Switch (Without RPO Code U68) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Sunroof Switch (Without RPO Code U68) > Page 820 Sunroof Opening Position Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 821 Sunroof / Moonroof Switch: Description and Operation SUNROOF OPENING POSITION SWITCH The Sunroof Opening Position Switch tracks the position of the glass through 2 limit switches: - Soft Stop limit - Vent limit The sunroof control module monitors the limit switches and based on the inputs determines the position of the sunroof glass. As a limit switch closes, the 5 volt reference will be shorted to the sunroof limit switch low reference circuit, pulling the 5 volt reference to 0 volts. The sunroof control module understands the position of the sunroof glass based on the different input combinations through the soft stop and vent limit switch inputs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch Replacement (w/o Overhead Console) Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (w/o Overhead Console) Sunroof Switch Replacement (w/o Overhead Console) Removal Procedure 1. Grasp the power sunroof switch on the left and right sides. Important: The switch must be rotated, pulled down on the left side, to be removed. 2. Use 2, small, flat-bladed tools in order to disengage the clips which are located at the front and rear of the power sunroof switch. Hold the flat-bladed tools parallel to the roof and push straight in. 3. Rotate the power sunroof switch toward the left side to disengage it from the mounting bracket and pull down. 4. Disconnect the electrical connector from the power sunroof switch. 5. Remove the power sunroof switch from the vehicle. Installation Procedure 1. Connect the electrical connector to the power sunroof switch. 2. Rotate the power sunroof switch back into the vehicle. 3. Firmly push the power sunroof switch into the headliner until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch Replacement (w/o Overhead Console) > Page 824 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (With Overhead Console) Sunroof Switch Replacement (With Overhead Console) Removal Procedure Important: The driver information center control module, and the power sunroof switch is serviced as a complete part. 1. Remove the overhead console. 2. Remove the driver information center control module, containing the power sunroof switch from the overhead console. Installation Procedure 1. Install the driver information center control module, containing the power sunroof switch to the overhead console. 2. Install the overhead console. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch Replacement (w/o Overhead Console) > Page 825 Sunroof / Moonroof Switch: Service and Repair Sunroof Opening Position Switch Replacement Sunroof Opening Position Switch Replacement Tools Required J 41718 Sunroof Timing Pins Removal Procedure Important: ^ The Sunroof Opening Position Switch (SOPS) (3) is aligned to the drive cables. The switch comes from the factory set to the window panel CLOSED position. A position lock pin (1) has been installed on the top of the switch. The pin (1) must remain until after the installation of the actuator and of the switch. The lock pin locks the drive gears in place and must be removed before operation of the sunroof module. ^ If you reuse a Sunroof Opening Position Switch, place the sunroof window panel in the CLOSED position. Install the sunroof timing pins J 41718. Install a position lock pin, or install 2 wires, such as the ends of a paper clip, then remove the SOPS from the sunroof module. The SOPS timing will be lost if you do not follow this procedure. 1. Position the sunroof window panel to the closed position. 2. Remove the sunroof module from the vehicle. Important: Before removing the SOPS from the sunroof module, the J 41718 sunroof timing pins must be installed to lock the cable/cam mechanism into position. 3. The cable/cam mechanisms, on both sides of the sunroof window, contain a set of timing holes. These holes are aligned to the sunroof window panel in the CLOSED position. Remove the left and right side front sunroof window panel screws. Align the timing holes. Use a flat-bladed tool to push the cable/cam mechanism forward or rearward. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch Replacement (w/o Overhead Console) > Page 826 Install the J 41718 sunroof timing pins into the left and right sunroof window panel screw holes. 4. Remove the sunroof actuator. 5. Disconnect the electrical connector from the SOPS (3). 6. Remove the SOPS screw (2) from the switch. 7. Hold down on both drive cables, and lift straight up to remove the SOPS from the sunroof module. Installation Procedure Important: The new SOPS comes with a position lock pin that is installed on top of the SOPS. This locks the timing gears in place. Do not remove this pin until after you have installed the SOPS and the actuator. 1. Keeping the position lock pin in the new SOPS, position the SOPS switch over the drive cables and press down. If the SOPS does not slide into position, the ridges on the drive cable housings will not go into the grooves on the back of the SOPS. Lift each cable into the SOPS, and press down on the SOPS assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch Replacement (w/o Overhead Console) > Page 827 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the Sunroof opening Position Switch screw (2) to the switch. Tighten Tighten the SOPS screw to 2 N.m (18 lb in). 3. Connect the electrical connector to the SOPS. 4. Install the sunroof actuator. 5. Remove the position lock pin (1) or the 2 wires from the switch. 6. Remove the 2 pins from the cable/cam mechanisms. 7. Install the left and right front sunroof window panel screws. Tighten Tighten the front sunroof window panel screws to 4 N.m (35 lb in). 8. Install the sunroof module, but do not install the headliner until after you have tested the sunroof operation. 9. Inspect the operation of the sunroof. 10. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Service and Repair Trunk / Liftgate Ajar Switch: Service and Repair REAR COMPARTMENT LID AJAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Open the rear compartment. 2. Remove the rear compartment lid latch. 3. Remove the rear compartment lid ajar lamp/switch to rear compartment lid latch screw (5). 4. Remove the compartment lid ajar lamp/switch (6) from the rear compartment lid latch (8). INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Service and Repair > Page 831 1. Position the rear compartment lid ajar lamp/switch (6) to the rear compartment lid latch (8). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear compartment lid ajar lamp/switch to rear compartment lid latch screw (5). Tighten Tighten the rear compartment lid ajar lamp/switch to rear compartment lid latch screw to 5 N.m (44 lb in). 3. Install the rear compartment lid latch. 4. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Lower Left Center Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 835 Rear Compartment Lid Release Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 836 Trunk / Liftgate Switch: Service and Repair REAR COMPARTMENT LID SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Release the LH instrument panel (IP) insulator tabs from the lower IP trim pad retainers for access. 2. Remove the LH fuse block access cover. 3. Remove the steering column opening filler panel screws. 4. Release the steering column opening filler panel retainers from the IP lower trim panel. Carefully lower the steering column opening filler panel away from the IP lower trim panel. 5. Disconnect the electrical connector from the rear compartment release switch. 6. Remove the rear compartment release switch. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 837 1. Install the rear compartment release switch. 2. Connect the electrical connector to the rear compartment release switch. 3. Align the steering column opening filler panel to the instrument panel (IP) lower trim panel. Install the steering column opening filler panel retainers to the IP lower trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the steering column opening filler panel screws. Tighten Tighten the steering column opening filler panel screws to 2 N.m (18 lb in). 5. Install the LH IP insulator tabs to the lower IP trim pad retainers. 6. Install the LH fuse block access cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 842 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector from brake fluid level sensor. 2. Remove the brake fluid level sensor. Using needle nose pliers, carefully depress the retaining tabs on the end of the brake fluid level sensor (1) and press the sensor through the reservoir to remove. Installation Procedure 1. Place the brake fluid level sensor (1) into the reservoir, press into place to secure the sensor retaining tabs. 2. Connect the electrical connector to the brake fluid level sensor (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the left side instrument panel insulator. 2. Remove the left carpet retainers. 3. Disconnect the electrical connector from the switch. 4. Remove the mounting screw. 5. Remove the parking brake indicator switch (1). Installation Procedure 1. Install the parking brake indicator switch (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the mounting screw. ^ Tighten the mounting screw to 3 Nm (26 inch lbs.). 3. Connect the electrical connector to the switch. Check the operation of the switch. 4. Install the left carpet retainers. 5. Install the left side instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair Traction Control Switch: Service and Repair Traction Control Switch Replacement (Impala) Removal Procedure 1. If equipped with column shift, apply the parking brake. 2. If equipped with column shift, position the transaxle shift control indicator to 1. 3. Adjust the steering wheel for access. 4. Remove the ignition switch cylinder bezel. 5. Remove the LH instrument panel (IP) fuse block access opening cover. 6. Remove the LH IP cluster trim plate screws. 7. Remove the IP cluster trim plate for access. Start at the left side of the IP cluster trim plate, grasp the trim plate and carefully pull rearward. Disengage enough IP cluster trim plate retainers in order to gain access the traction control switch. 8. Disconnect the electrical connector (1) from the traction control switch (2). 9. Remove the traction control switch (1) from the IF, cluster trim plate (2). Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Page 849 1. Install the traction control switch (1) to the IP cluster trim plate (2). 2. Connect the electrical connector (1) to the traction control switch (2). 3. Align and carefully press the IP cluster trim plate into the IP trim pad. Make sure all of the retainers are fully engaged. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the LH IP cluster trim plate screws. ^ Tighten the IP cluster trim plate screws to 2 Nm (18 inch lbs.). 5. Install the LH instrument panel (IP) fuse block access opening covers. 6. Install the ignition switch cylinder bezel. 7. Return the steering wheel to the original position. 8. If equipped with a column shift, position the transaxle shift control indicator to Park. 9. If equipped with column shift, release the parking brake. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement - Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement - Front Wheel Speed Sensor Replacement - Front Removal Procedure Important: The front wheel speed sensors and rings are integral with the hub and bearing assemblies. If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. Do not service the harness pigtail individually because the harness pigtail is part of the sensor. 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting. 2. Remove the front tire and wheel assembly. 3. Disconnect the front wheel speed sensor jumper harness electrical connector (1). 4. Remove the hub and bearing assembly (2). Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement - Front > Page 854 1. Install the hub and bearing assembly (2) to the vehicle. 2. Install the front wheel speed sensor jumper harness electrical connector (1). 3. Install the wheel and tire assembly. 4. Lower the vehicle. 5. Turn the ignition switch to the ON position with the engine off. 6. Perform the Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement - Front > Page 855 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement - Rear Wheel Speed Sensor Replacement - Rear Removal Procedure Important: The rear wheel speed sensors and rings are integral with the hub and bearing assemblies. If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting. 2. Remove the rear tire and wheel assembly. 3. Disconnect the electrical connector from the rear wheel speed sensor. 4. Remove the hub and bearing assembly (1). Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement - Front > Page 856 1. Install the hub and bearing assembly (1) to the vehicle. 2. Connect the electrical connector to the rear wheel speed sensor. 3. Install the wheel and tire assembly. 4. Lower the vehicle. 5. Turn the ignition switch to the ON position, with the engine off. 6. Perform the Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 862 Engine Coolant Temperature (ECT) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 863 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Partially drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the thermostat housing. 3. Disconnect the ECT sensor electrical connector. 4. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. 1. Coat the threads with sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 864 3. Connect the ECT sensor electrical connector. 4. Install the thermostat housing. 5. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations Lower Center Of Instrument Panel (Without RPO Code 9C1/9C3) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 869 Lower Center Of Instrument Panel (Without RPO Code 9C1/9C3) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 870 Cruise Control Release Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 871 Brake Switch (Cruise Control): Adjustments CRUISE RELEASE SWITCH ADJUSTMENT IMPORTANT: The cruise control release switch and the stop lamp switch are adjusted together. Incorrect adjustment of either of these switches may cause premature brake lining wear or the incorrect operation of the cruise control system. 1. Remove the left instrument panel insulator. 2. Press the brake pedal fully. 3. Push the switches into the retainers until the switches are fully seated. 4. Pull the brake pedal fully rearward against the pedal stop until the audible clicks can no longer be heard. 5. Measure the brake pedal travel distances from the centerline of the brake pedal pad. Compare the measurements to the following values. The comparison of the values can verify that the cruise control release switch and the stop lamp switch are correctly adjusted: The cruise control release switch and the stop lamp switch contacts must actuate at 3.5-12.5 mm (0.125-0.500 in) of brake pedal travel. - Nominal actuation of the stop lamp switch contacts occurs about 4.5 mm (0.2 in) beyond the point of cruise control release switch actuation. 6. Install the left instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 872 Brake Switch (Cruise Control): Service and Repair CRUISE RELEASE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the left instrument panel insulator. 2. Disconnect the cruise release switch electrical connector. 3. Remove the cruise release switch from the cruise release switch retainer on the brake pedal bracket. INSTALLATION PROCEDURE 1. Install the cruise release switch to the cruise release switch retainer on the brake pedal bracket. 2. Connect the cruise release switch electrical connector. 3. Adjust the cruise release switch. Refer to Cruise Release Switch Adjustment. 4. Install the left side instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 876 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the engine oil drain plug in order to drain the engine oil. 3. Disconnect the oil level sensor electrical connector. 4. Remove the engine oil level sensor from the oil pan. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the engine oil level sensor to the oil pan. - Tighten the sensor to 20 Nm (15 ft. lbs.). 2. Connect the oil level sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair > Page 881 3. Install the engine oil drain plug. - Tighten the plug to 30 Nm (22 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with engine oil. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations > Page 885 Lower Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations > Page 886 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations > Page 887 Engine Oil Level Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Lower Right Rear Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 891 Lower Right Rear Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 892 Engine Oil Pressure (EOP) Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the engine oil pressure switch electrical connector. 3. Remove the oil pressure switch. Installation Procedure Notice; Refer to Fastener Notice in Service Precautions. 1. Install the engine oil pressure switch. - Tighten the switch to 16 Nm (12 ft. lbs.). 2. Connect the engine oil pressure switch electrical connector. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Front Of Vehicle Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 900 Ambient Air Temperature Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 901 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE GAGE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector from the ambient temperature sensor that is located on the front radiator air baffle. 3. Remove the ambient temperature sensor from the radiator air baffle. INSTALLATION PROCEDURE 1. Install the ambient temperature sensor to the radiator air baffle. 2. Connect the electrical connector to the ambient temperature sensor. 3. Lower the vehicle. 4. Drive the vehicle at a speed of 32 km/h (20 mph) for approximately 1 1/2 minutes or at a speed of 72 km/h (45 mph) for approximately 1 minute in order to obtain the ambient update. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 905 Left Front Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 906 Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 907 A/C Refrigerant Pressure Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 908 Refrigerant Pressure Sensor / Switch: Description and Operation A/C REFRIGERANT PRESSURE SENSOR The A/C refrigerant pressure sensor is a 3-wire piezoelectric pressure transducer. A 5-volt reference, low reference, and signal circuits enable the sensor to operate. The A/C pressure signal can be between 0-5 volts. When the A/C refrigerant pressure is low, the signal value is near 0 volts. When the A/C refrigerant pressure is high, the signal value is near 5 volts. The A/C refrigerant pressure sensor protects the A/C system from operating when an excessively high or low pressure condition exists. The PCM disables the compressor clutch under the following conditions: - A/C pressure is more than 3034 kPa (440 psi). The clutch will be enabled after the pressure decreases to less than 2068 kPa (300 psi). - A/C pressure is less than 241 kPa (35 psi). The clutch will be enabled after the pressure increases to more than 248 kPa (36 psi). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 909 Refrigerant Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) REFRIGERANT PRESSURE SENSOR REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner assembly. 2. Disconnect the electrical connector from the A/C refrigerant pressure sensor. 3. Remove the A/C refrigerant pressure sensor from the evaporator tube. INSTALLATION PROCEDURE 1. Replace the O-ring seal for the A/C refrigerant pressure sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the A/C refrigerant pressure sensor to the evaporator tube. Tighten Tighten the sensor to 4.7 N.m (41 lb in). 3. Connect the electrical connector to the A/C refrigerant pressure sensor. 4. Install the air cleaner assembly. 5. Leak test the fittings of the component using J 39400-A. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications Fuel Gauge Sender: Specifications FUEL LEVEL SPECIFICATIONS The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 914 Fuel Gauge Sender: Locations Fuel Pump And Sender Assembly Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 915 Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 916 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 917 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Remove the fuel sender assembly. 2. Disconnect the fuel level sensor electrical connector. 3. Remove the fuel level sensor (5) from the fuel sender assembly. INSTALLATION PROCEDURE 1. Install the fuel level sensor (5) to the fuel sender assembly. 2. Connect the fuel level sensor electrical connector. 3. Install the fuel sender assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the left side instrument panel insulator. 2. Remove the left carpet retainers. 3. Disconnect the electrical connector from the switch. 4. Remove the mounting screw. 5. Remove the parking brake indicator switch (1). Installation Procedure 1. Install the parking brake indicator switch (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the mounting screw. ^ Tighten the mounting screw to 3 Nm (26 inch lbs.). 3. Connect the electrical connector to the switch. Check the operation of the switch. 4. Install the left carpet retainers. 5. Install the left side instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams Ambient Light Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 925 Ambient Light Sensor: Service and Repair DAYTIME RUNNING LAMPS (DRL) AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the garnish molding from the left windshield pillar. 2. Starting at the left side, carefully lift upwards on the instrument panel (IP) upper trim panel in order to release the retainers from the IP upper trim pad. Work towards the right in order to access the daytime running lamp (DRL) ambient light sensor. 3. Remove the DRL ambient light sensor from the IP upper trim panel by twisting the sensor 1/4 turn counterclockwise. 4. Remove the DRL ambient light sensor from the DRL ambient light sensor connector. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 926 1. Install the daytime running lamp (DRL) ambient light sensor to the DRL ambient light sensor connector. 2. Position the DRL ambient light sensor to the opening in the instrument panel (IP) upper trim panel. Twist the DRL ambient light sensor 1/4 turn clockwise. 3. Verify that the DRL ambient light sensor wiring harness will not be pinched when the IP upper trim panel is installed. Working from right to left, press down on the IP upper trim panel in order to engage the retainers to the IP upper trim pad. 4. Install the garnish molding to the left windshield pillar. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams Brake Light Switch: Diagrams Stop Lamp Switch, C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 930 Stop Lamp Switch, C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 931 Brake Light Switch: Adjustments STOP LAMP SWITCH ADJUSTMENT 1. With the brake pedal in the fully released position, ensure that the stop lamp plunger is fully depressed against the brake pedal shanks. 2. Fully insert the stop lamp switch and the cruise control switch, if equipped, into the brake pedal bracket. 3. Push the brake pedal forward in order to set the brake push rod into the booster. NOTE: Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear. 4. Pull the brake pedal to the rear, against the internal stop. This adjusts both the stop lamp switch and the cruise control switch. 5. Inspect the stop lamp switch for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 932 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the left instrument panel (I/P) insulator. 2. Disconnect the electrical connector from the stop lamp switch. 3. Remove the stop lamp switch (2) from the brake pedal bracket. INSTALLATION PROCEDURE 1. Install the stop lamp switch (2) to the brake pedal bracket. 2. Connect the electrical connector to the stop lamp switch. 3. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment. 4. Install the left I/P insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Steering Wheel Controls (Radio) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 936 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 937 Steering Wheel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 938 Steering Wheel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations Left Front Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 942 Fog Lamp Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 943 Fog/Driving Lamp Switch: Service and Repair FOG LAMP SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the trim plate bezel from the instrument panel (I/P) cluster. 2. Remove the headlamp switch assembly screws. 3. Pull the headlamp switch assembly from the I/P. 4. Disconnect the electrical connector from the fog lamp switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 944 5. Remove the fog lamp switch from the back of the headlamp switch assembly. INSTALLATION PROCEDURE 1. Install the fog lamp switch through the back of the headlamp switch assembly by pressing the switch into place until fully seated. 2. Connect the electrical connector to the fog lamp switch. 3. Install the headlamp switch assembly to the I/P. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 945 4. Install the headlamp switch assembly screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the trim plate bezel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Left Center Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 949 Hazard Warning Switch: Diagrams Hazard Switch Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 950 Hazard Switch Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement Hazard Warning Switch: Service and Repair Hazard Warning Switch Replacement HAZARD WARNING SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Apply the parking brake. 2. Using a small, flat-bladed tool, gently remove the bezel from the ignition lock cylinder. 3. If the vehicle is equipped with a column shift, position the transaxle shift control indicator to 1. 4. Adjust the steering wheel for access. 5. For the Impala, remove the right and the left access covers from the instrument panel (I/P) fuse block. For the Monte Carlo, remove the left access cover from the I/P fuse block. 6. Remove the steering column filler. 7. For the Monte Carlo, open the instrument panel compartment door. 8. Remove the I/P cluster trim plate screws. 9. Start at the left side of the I/P cluster trim plate. Grasp the trim plate and carefully pull rearward. Disengage the I/P cluster trim plate in order to easily access the hazard warning switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement > Page 953 10. Disconnect the electrical connector from the hazard warning switch. 11. Remove the hazard warning switch from the I/P cluster trim plate. INSTALLATION PROCEDURE 1. Install the hazard warning switch to the I/P cluster trim plate. 2. Connect the electrical connector to the hazard warning switch. 3. Press the I/P cluster trim plate into the I/P trim pad, until all of the retainers are fully seated. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement > Page 954 4. Install the I/P cluster trim plate screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. For the Monte Carlo, install the left access cover to the I/P fuse block. For the Impala, install the right and the left access covers to the I/P fuse block. 6. Install the steering column filler. 7. For the Monte Carlo, close the I/P compartment door. 8. Reposition the steering wheel to the original position. 9. If the vehicle is equipped with column shift, position the transaxle shift control indicator to Park. 10. Install the bezel to the ignition lock cylinder. 11. Release the parking brake. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement > Page 955 Hazard Warning Switch: Service and Repair Emergency Vehicle Interior Switch Replacement EMERGENCY VEHICLE INTERIOR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the trim plate bezel from the instrument panel (I/P) cluster. 2. Remove the headlamp switch assembly screws. 3. Pull the headlamp switch assembly from the I/P. 4. Disconnect the electrical connector from the emergency vehicle interior switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement > Page 956 5. Remove the emergency vehicle interior switch from the back of the headlamp switch assembly. INSTALLATION PROCEDURE 1. Install the emergency vehicle interior switch through the back of the headlamp switch assembly by pressing the switch into place until fully seated. 2. Connect the electrical connector to the emergency vehicle interior switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement > Page 957 3. Install the headlamp switch assembly to the I/P. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the headlamp switch assembly screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the trim plate bezel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Left Front Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 963 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 964 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 965 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 966 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 967 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 968 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 969 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 970 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 971 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 972 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 973 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 974 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 975 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 976 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 977 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 978 Headlamp Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 979 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 980 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 981 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 982 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 983 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 984 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 985 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 986 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 987 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 988 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 989 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 990 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 991 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 992 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 993 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 994 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 995 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 996 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 997 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 998 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 999 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1000 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1001 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1002 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1003 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1004 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1005 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1006 Headlamp Switch: Connector Views Headlamp Switch Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1007 Headlamp Switch Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 1008 Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate bezel. 2. Remove the screws from the headlamp switch housing. 3. Remove the headlamp switch housing from the instrument panel. 4. Disconnect the electrical connector from the headlamp switch. 5. Disconnect the electrical connector from the foglamp switch. 6. Remove the foglamp switch from the headlamp switch housing, using a small flat bladed tool. INSTALLATION PROCEDURE 1. Install the foglamp switch to the headlamp switch housing, pressing into place until fully seated. 2. Connect the electrical connector to the headlamp switch. 3. Connect the electrical connector to the foglamp switch. 4. Install the headlamp housing switch to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the screws to the headlamp housing switch. Tighten Tighten the headlamp housing switch screws to 2 N.m (18 lb in). 6. Install the instrument panel cluster trim plate bezel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Steering Wheel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1012 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1013 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1014 Steering Wheel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 1015 Steering Wheel Controls (Radio) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement Turn Signal Switch: Service and Repair Multifunction Switch Replacement Multifunction, Turn Signal Switch Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the upper and lower trim covers. Important: The abrasion sleeve located on the steering column wire harness assembly must be reinstalled. Make note of what connector is coming out of the abrasion sleeve for installation purposes. 3. Remove the wire harness assembly (1) from the wire harness strap (2). 4. Disconnect the turn signal and multifunction switch assembly connector from the SIR system coil connector. 5. Slide the 2 connectors (2) of the turn signal and multifunction switch assembly out of the bulkhead connector (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 1018 6. Remove the 2 pan head tapping screws (1) and (3) from the turn signal and multifunction switch assembly (2). 7. Remove the turn signal and multifunction switch assembly (2) from the steering column tilt head assembly. Installation Procedure 1. Install the turn signal and multifunction switch assembly (2) onto the steering column tilt head assembly. Notice: Refer to Fastener Notice in Service Precautions. Important: Be sure that the electrical contact of the turn signal and multifunction switch assembly (2) rests on the turn signal cancel cam assembly. 2. Screw the 2 pan head tapping screws (1) and (3) into the turn signal and multifunction assembly (2). ^ Tighten the top pan head tapping screw (1) to 3 Nm (27 in. lbs.). ^ Tighten the side pan head tapping screw (3) to 7 Nm (62 in. lbs.). 3. Slide the 2 connectors (2) of the turn signal and multifunction switch assembly into the bulkhead connector (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 1019 4. Connect the turn signal and multifunction switch assembly connector to the SIR coil connector. Important: The abrasion sleeve must be installed back onto the steering column wire harness assembly. The ignition lock cylinder case wires and connector must be hanging out of the middle of the abrasion sleeve. 5. Install the wire harness assembly (1) into the wire harness strap (2). 6. Install the upper and lower trim covers. 7. Enable the SIR system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 1020 Turn Signal Switch: Service and Repair Turn Signal Cancel Cam and Steering Shaft Upper Bearing Spring Turn Signal Cancel Cam and Steering Shaft Upper Bearing Spring Replacement ^ Tools Required J 23653-SIR Steering Column Lock Plate Compressor - J 42137 Cam Orientation Plate Adapter Removal Procedure 1. Disconnect the battery negative cable. Caution: Refer to SIR Caution in Service Precautions. 2. Disable the SIR system. 3. Remove the inflator module. 4. Remove the steering wheel. 5. Remove the SIR coil from the steering column upper shaft. 6. Allow the SIR coil to hang. 7. Remove the wave washer (1) from the steering shaft (2). 8. Compress the shaft lock plate using J23653-SIR and J42137. 9. Remove the bearing retainer (1) from the steering shaft. 10. Remove J23653-S/R and J42137 from the steering shaft. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 1021 11. Remove the shaft lock shield (5) from the steering shaft. 12. Remove the turn signal cancel cam (4) from the steering shaft. 13. Remove the upper bearing spring (3) from the steering shaft. 14. Remove the upper bearing inner race seat (2) from the steering shaft. 15. Remove the inner race (1) from the steering shaft. Installation Procedure 1. Lubricate the inner race (1) with GM P/N 12345718 (Canadian P/N 10953516). 2. Install the inner race (1) onto the steering shaft. 3. Install the upper bearing inner race seat (2) onto the steering shaft. 4. Install the upper bearing spring (3) onto the steering shaft. 5. Lubricate the lower brass surface of the turn signal cancel cam (4) with GM P/N 12377900 (Canadian P/N 10953529). 6. Install the turn signal cancel cam (4) onto the steering shaft. 7. Install the shaft lock shield (5) onto the steering shaft. 8. Compress the shaft lock shield (2) using J 23653-SIR and J 42137. 9. Install the new bearing retainer (1) onto the steering shaft. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 1022 10. Firmly seat the bearing retainer (1) into the groove on the steering shaft. 11. Remove J 23653-SIR and J 42137from the steering shaft. 12. Install the wave washer (1) onto the steering shaft (2). 13. Install the SIR coil. 14. Install the steering wheel. 15. Install the inflator module. 16. Enable the SIR system. 17. Connect the battery negative cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations Left Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1028 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1029 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1030 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1031 Mass Air Flow (MAF) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1032 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. IMPORTANT: The mass air flow (MAF) sensor is attached to the throttle body assembly. 2. Disconnect the MAF sensor electrical connector (8). 3. Remove the MAF sensor screws (9). 4. Remove the MAF sensor (1). INSTALLATION PROCEDURE 1. Install the MAF sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF sensor screws (9). Tighten Tighten the screws to 3 N.m (27 lb in). 3. Connect the MAF sensor electrical connector (8). 4. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1036 Right Middle Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1037 Camshaft Position (CMP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1038 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The camshaft position (CMP) sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor does not directly affect the operation of the ignition system. The CMP sensor information is used by the powertrain control module (PCM) to determine the position of the valve train relative to the CKP. By monitoring the CMP and CKP signals the PCM can accurately time the operation of the fuel injectors. The CMP sensor shares 12-volt and low reference circuits with the CKP sensor. The CMP signal circuit is input to the ICM. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1039 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the coolant recovery reservoir. 2. Remove the drive belt. 3. Disconnect the electrical connector (2) from the camshaft position sensor (1). 4. Remove the camshaft position sensor bolt. 5. Remove the camshaft position sensor from the engine front cover. INSTALLATION PROCEDURE 1. Install the camshaft position sensor to the engine front cover. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 1040 2. Install the camshaft position sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 3. Connect the electrical connector (2) to the camshaft position sensor (1). 4. Install the drive belt. 5. Install the coolant recovery reservoir. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1044 Engine Coolant Temperature (ECT) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1045 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Partially drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the thermostat housing. 3. Disconnect the ECT sensor electrical connector. 4. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. 1. Coat the threads with sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 1046 3. Connect the ECT sensor electrical connector. 4. Install the thermostat housing. 5. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1050 Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1051 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1052 Camshaft Position (CKP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1053 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSORS The crankshaft position (CKP) sensor has a 4-wire harness connector that plugs into the CKP sensor and connects to the ignition control module (ICM). The CKP sensor contains 2 hall-effect switches in 1 housing, and shares a magnet between the switches. The magnet and each hall-effect switch are separated by an air gap. A hall-effect switch is a solid state switching device that produces a digital ON/OFF pulse when a rotating element passes the sensor pick-up and interrupts the magnetic field of the sensor. The rotating element is called an interrupter ring or blade. There are two interrupter rings built into the crankshaft balancer. The outer ring and the outer switch provide the ICM with 18X signals or 18 identical pulses per crankshaft revolution. The inner ring and the inner switch provide the ICM with 3 pulses per revolution, each 1 of different duration. This is called the sync pulse. Each sync pulse represents a pair of companion cylinders. The ICM supplies a 12-volt and a low reference circuit to the CKP sensor, which is also shared by the camshaft position (CMP) sensor. The 18X reference pulses are passed from the CKP sensor to the ICM on the CKP sensor 1 signal circuit. The sync pulses are passed from the CKP sensor to the ICM on the CKP sensor 2 signal circuit. The ICM uses the 18X and sync pulses to determine the crankshaft position by counting how many ON-OFF 18X pulses occur during a sync pulse. With this dual interrupter ring arrangement the ICM can identify the correct pair of cylinders to fire within as little as 120 degrees of crankshaft rotation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1054 Crankshaft Position Sensor: Testing and Inspection CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The ignition control module (ICM) monitors the crankshaft position (CKP) sensor sync signal when the engine is cranking. The CKP sync signal is passed from the CKP sensor to the ICM on the CKP sensor 2 signal circuit. The CKP sync signal is used to determine the correct cylinder pair and initiate the ignition coil firing sequence. The 18X reference pulses are passed from the CKP sensor to the ICM on the CKP sensor 1 signal circuit. The 18X reference pulses are used for fuel injection and ignition control. After the ICM receives both signals, the ICM passes the 18X and 3X reference signals to the powertrain control module (PCM). The camshaft position sensor and the CKP sensor share a 12-volt reference and a low reference circuit. The CKP sensor consists of the following circuits: A 12-volt reference circuit - A low reference circuit - A CKP sensor 1 signal circuit - A CKP sensor 2 signal circuit TEST Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1055 Steps 4-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1056 Steps 8-14 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1057 Steps 15-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1058 Steps 21-26 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1059 Steps 27-28 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 1060 Steps 29-31 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 4.1. Accelerate to wide open throttle (WOT). 4.2. Release throttle when fuel cut-off occurs. 4.3. Observe fuel cut-off specification for applicable engine. 4.4. Engine should not accelerate beyond calibrated RPM value. 4.5. Release throttle immediately if value is exceeded. 4.6. Block drive wheels. 4.7. Set parking brake. 4.8. DO NOT apply brake pedal. 4.9. Cycle ignition from OFF to ON. 4.10. Apply and hold brake pedal. 4.11. Start and idle engine. 4.12. Turn A/C OFF. 4.13. Vehicle must remain in Park or Neutral. 4.14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure.The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - Crankshaft position (CKP) sensors activity - If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity - If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool and perform the following: IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 5.1. Accelerate to WOT. 5.2. Release when fuel cut-off occurs. 5.3. Test in progress. 6. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 . If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC. 7. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set Engine replacement - PCM replacement - A harmonic balancer replacement - Crankshaft replacement - CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1063 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the right splash shield cover. 4. Remove the crankshaft balancer. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the CKP sensor shield (1). 7. Remove the CKP sensor bolts. 8. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1064 1. Position the CKP sensor to the block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolts. Tighten Tighten the bolts to 30 N.m (22 lb ft) 3. Install the CKP sensor shield (1). 4. Connect the CKP sensor electrical connector. 5. Install the crankshaft balancer. 6. Install the right splash shield cover. 7. Lower the vehicle. 8. Connect the negative battery cable. 9. Perform the Crankshaft Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Fuel Pump And Sender Assembly Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1068 Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 1069 Fuel Level Sensor: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Remove the fuel sender assembly. 2. Disconnect the fuel level sensor electrical connector. 3. Remove the fuel level sensor (5) from the fuel sender assembly. INSTALLATION PROCEDURE 1. Install the fuel level sensor (5) to the fuel sender assembly. 2. Connect the fuel level sensor electrical connector. 3. Install the fuel sender assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations Fuel Pump And Sender Assembly Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1073 Fuel Tank Pressure (FTP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1074 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 1075 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank pressure sensor (7) from the fuel sender assembly (1). 2. Disconnect the negative battery cable. 3. Remove the fuel sender assembly. INSTALLATION PROCEDURE 1. Install the new fuel tank pressure sensor (7) to the fuel sender assembly (1). 2. Install the fuel sender assembly. 3. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Intake Air Temperature (IAT) Sensor: Locations Intake Air Temperature Sensor (IAT) is in the air induction tube. 3. Intake Air Temperature (IAT) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature (IAT) Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1081 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1082 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1083 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1084 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1085 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1086 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1087 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1088 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1089 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1090 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1091 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1092 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1093 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1094 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1095 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1096 Intake Air Temperature (IAT) Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1097 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1098 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1099 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1100 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1101 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1102 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1103 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1104 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1105 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1106 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1107 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1108 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1109 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1110 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1111 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1112 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1113 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1114 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1115 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1116 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1117 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1118 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1119 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1120 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1121 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1122 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1123 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 1124 Intake Air Temperature (IAT) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 1125 Intake Air Temperature (IAT) Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector. 2. Remove the IAT sensor (3) with a twisting and pulling motion. INSTALLATION PROCEDURE 1. Install the IAT sensor (3). 2. Connect the IAT sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Lower Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1129 Rear Middle Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1130 Knock Sensor: Diagrams Knock Sensor (KS) 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1131 Knock Sensor (KS) 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 1132 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This KS system uses one or two broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement Knock Sensor: Service and Repair Knock Sensor (KS) 1 Replacement KNOCK SENSOR (KS) 1 REPLACEMENT REMOVAL PROCEDURE CAUTION: Hot engine coolant may cause severe burns. Although the cooling system has been drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of the knock sensor. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Disconnect the knock sensor electrical connector (2). 4. Remove the knock sensor (1). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. 1. Install the knock sensor (1). Tighten Tighten the knock sensor to 19 N.m (14 lb ft). 2. Connect the knock sensor electrical connector (2). 3. Lower the vehicle. 4. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement > Page 1135 Knock Sensor: Service and Repair Knock Sensor (KS) 2 Replacement KNOCK SENSOR (KS) 2 REPLACEMENT REMOVAL PROCEDURE CAUTION: Hot engine coolant may cause severe burns. Although the cooling system has been drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of the knock sensor. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Remove the bolts (2) from the knock sensor heat shield (1). 4. Disconnect the knock sensor electrical connector (3) from the knock sensor. 5. Remove the knock sensor (4). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. 1. Install the knock sensor (4). Tighten Tighten the knock sensor to 19 N.m (14 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement > Page 1136 2. Install the knock sensor heat shield. Tighten Tighten the bolts to 60 N.m (44 lb ft). 3. Connect the knock sensor electrical connector. 4. Lower the vehicle. 5. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1140 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1141 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1142 Manifold Absolute Pressure (MAP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1143 Manifold Pressure/Vacuum Sensor: Testing and Inspection MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR DIAGNOSIS CIRCUIT DESCRIPTION VIN K The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure which gives an indication of the engine load. The MAP sensor has a 5-volt reference circuit, a low reference circuit, and a signal circuit. The powertrain control module (PCM) supplies 5 volts to the MAP sensor on the 5-volt reference circuit and provides a ground on the low reference circuit. The MAP sensor provides a signal to the PCM on the MAP sensor signal circuit, which is relative to the pressure changes in the manifold. With low MAP, such as during idle or deceleration, the PCM should detect a low MAP sensor signal voltage. With high MAP, such as ignition ON, engine OFF, or wide open throttle (WOT), the PCM should detect a high MAP sensor signal voltage. This MAP sensor will indicate pressure between 10-104 kPa. The MAP sensor is also used in order to calculate the barometric pressure (BARO) when the ignition switch is turned ON, with the engine OFF. The BARO reading may also be updated whenever the engine is operated at WOT. The PCM monitors the MAP sensor signal for voltage outside of the normal range. If the PCM detects a MAP sensor signal voltage that is excessively low, DTC P0107 sets. If the PCM detects a MAP sensor signal voltage that is excessively high, DTC P0108 sets. TEST DESCRIPTION Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1144 Steps 4-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1145 Steps 6-10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1146 Steps 11-14 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1147 Steps 15-16 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1148 Steps 17-22 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1149 Steps 23-29 The number below refers to the step number on the diagnostic table. 4. This step tests the MAP sensor's ability to correctly indicate BARO. 12. The measurement noted in this step will be used in subsequent steps if the measurement does not exceed the specified value. 15. This step calculates the resistance in the 5-volt reference circuit. 16. This step calculates the resistance in the low reference circuit. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 1150 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT On the L36, the manifold absolute pressure (MAP) sensor is mounted to the positive crankcase ventilation (PCV) valve cover. Removal Procedure 1. Remove the fuel injector sight shield. 2. Disconnect the MAP sensor electrical connector. 3. Carefully release the locking tabs holding the MAP (1) sensor to the PCV valve cover (2) just enough to remove the MAP sensor. 4. Pull the MAP sensor straight out of PCV valve cover. Installation Procedure 1. Ensure that the seal is installed on the MAP sensor and that the seal is not damaged. 2. Position and install the MAP sensor (1) to the PCV valve cover (2). Ensure that the locking tabs engage to hold the MAP sensor to the PCV valve cover. 3. Connect the MAP sensor electrical connector. 4. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 1154 Lower Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 1155 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 1156 Engine Oil Level Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the engine oil pressure switch electrical connector. 3. Remove the oil pressure switch. Installation Procedure Notice; Refer to Fastener Notice in Service Precautions. 1. Install the engine oil pressure switch. - Tighten the switch to 16 Nm (12 ft. lbs.). 2. Connect the engine oil pressure switch electrical connector. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Upper Left Rear Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1163 Oxygen Sensor: Diagrams Heated Oxygen Sensor (HO2S) Sensor 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 1164 Heated Oxygen Sensor (HO2S) Sensor 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) 1 Replacement Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 1 Replacement HEATED OXYGEN SENSOR (HO2S) 1 REPLACEMENT TOOLS REQUIRED J 39194 Oxygen Sensor Wrench NOTE: The Heated Oxygen Sensor (HO2S) and the Oxygen Sensor use a permanently attached pigtail and connector. Do not remove this pigtail from the Heated Oxygen Sensor. Damage or the removal of the pigtail or the connector could affect the proper operation of the sensor. Take care when handling the HO2S and the O2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Also avoid using cleaning solvents of any type. Do not drop the HO2S or the O2S. Do not roughly handle the HO2S or the O2S. Removal Procedure NOTE: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. 1. Remove the fuel injector sight shield. 2. Remove the heated oxygen sensor (HO2S) electrical CPA retainer. 3. Disconnect the HO2S wiring harness connector (3) from the HO2S electrical connector (4). 4. Remove the HO2S electrical connector (4) from the fuel injector sight shield bracket (1). IMPORTANT: Remove the oxygen sensor with the engine temperature above 48°C (120°F). Otherwise the oxygen sensors may be difficult to remove. 5. Use the J 39194 to remove the HO2S (2). Installation Procedure NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: A special anti-seize compound is used on the oxygen sensor (1) threads. New service sensors should already have the compound applied to the threads. Coat the threads of a reused sensor with anti-seize compound P/N 12377953 or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) 1 Replacement > Page 1167 1. Install the rear oxygen sensor in the right exhaust manifold. Tighten Use the J 39194 to tighten the HO2S to 41 N.m (30 lb ft). 2. Connect the HO2S electrical connector (4) to the wiring harness connector (3). 3. Install the HO2S electrical connector (4) to the fuel injector sight shield bracket (1). 4. Install the HO2S electrical CPA retainer. 5. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) 1 Replacement > Page 1168 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 2 Replacement HEATED OXYGEN SENSOR (HO2S) 2 REPLACEMENT TOOLS REQUIRED J 39194 Oxygen Sensor Wrench NOTE: The Heated Oxygen Sensor (HO2S) and the Oxygen Sensor use a permanently attached pigtail and connector. Do not remove this pigtail from the Heated Oxygen Sensor. Damage or the removal of the pigtail or the connector could affect the proper operation of the sensor. Take care when handling the HO2S and the O2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Also avoid using cleaning solvents of any type. Do not drop the HO2S or the O2S. Do not roughly handle the HO2S or the O2S. Removal Procedure NOTE: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the HO2S electrical connector retaining tab (1) from the HO2S electrical connector (2). 3. Disconnect the HO2S electrical connector from the HO2S electrical connector (2). 4. Use the J 39194 to remove the HO2S from the exhaust pipe. Installation Procedure NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: A special anti-seize compound is used on the oxygen sensor threads. New service sensors should already have the compound applied to the threads. Coat the threads of a reused sensor with anti-seize compound P/N 12377953 or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) 1 Replacement > Page 1169 1. Install the oxygen sensor (4) to the exhaust pipe. Tighten Use the J 39194 to tighten the oxygen sensor to 41 N.m (30 lb ft). 2. Connect the HO2S connector (4) to the HO2S electrical connector (2). 3. Install the retaining tab (1) to the HO2S electrical connector. 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set Throttle Position Sensor: Customer Interest Engine Controls - Intermittent Chuggle/No DTC's Set Bulletin No.: 05-06-04-058 Date: September 07, 2005 TECHNICAL Subject: Intermittent Chuggle or Fishbite on Light Acceleration or at Highway Speeds with No Diagnostic Trouble Codes (DTCs) (Replace Throttle Position ( TPS) Sensor) Models: 1995-1999 Buick Riviera 1995-2004 Buick Regal 1995-2005 Buick LeSabre, Park Avenue 1997-2005 Buick Century 1995-2001 Chevrolet Lumina 1995-2002 Chevrolet Camaro 1995-2005 Chevrolet Monte Carlo 2000-2005 Chevrolet Impala 1995-1997 Oldsmobile Cutlass Supreme, Ninety Eight 1995-1999 Oldsmobile Eighty Eight 1998-2002 Oldsmobile Intrigue 1995-2002 Pontiac Firebird 1995-2003 Pontiac Grand Prix 1995-2005 Pontiac Bonneville with 3800 V6 Engine (VIN K - RPO L36) Condition Some customers may comment on an intermittent chuggle or fishbite on light acceleration or at steady-state highway speeds (typically 80-105 km/h [50-65 mph]) with no PCM DTCs set. This condition may lead the technician to suspect the TCC circuit or torque converter. Cause This condition may be caused by intermittent operation of the Throttle Position (TPS) Sensor. Correction In observed cases, the Tech 2(R) is not fast enough to consistently detect this condition during a snapshot. It is recommended to use a DVOM set to the min/max recording mode. Connect the DVOM at the TPS connector (positive lead to TPS feedback signal pin and negative lead to TPS ground pin). Duplicate this condition by driving the vehicle. If the voltage dropout (less than 0.45 v) is recorded on the DVOM, replace the TPS sensor and re-evaluate the vehicle before continuing with other driveability or transmission diagnosis. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set > Page 1178 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls Intermittent Chuggle/No DTC's Set Throttle Position Sensor: All Technical Service Bulletins Engine Controls - Intermittent Chuggle/No DTC's Set Bulletin No.: 05-06-04-058 Date: September 07, 2005 TECHNICAL Subject: Intermittent Chuggle or Fishbite on Light Acceleration or at Highway Speeds with No Diagnostic Trouble Codes (DTCs) (Replace Throttle Position ( TPS) Sensor) Models: 1995-1999 Buick Riviera 1995-2004 Buick Regal 1995-2005 Buick LeSabre, Park Avenue 1997-2005 Buick Century 1995-2001 Chevrolet Lumina 1995-2002 Chevrolet Camaro 1995-2005 Chevrolet Monte Carlo 2000-2005 Chevrolet Impala 1995-1997 Oldsmobile Cutlass Supreme, Ninety Eight 1995-1999 Oldsmobile Eighty Eight 1998-2002 Oldsmobile Intrigue 1995-2002 Pontiac Firebird 1995-2003 Pontiac Grand Prix 1995-2005 Pontiac Bonneville with 3800 V6 Engine (VIN K - RPO L36) Condition Some customers may comment on an intermittent chuggle or fishbite on light acceleration or at steady-state highway speeds (typically 80-105 km/h [50-65 mph]) with no PCM DTCs set. This condition may lead the technician to suspect the TCC circuit or torque converter. Cause This condition may be caused by intermittent operation of the Throttle Position (TPS) Sensor. Correction In observed cases, the Tech 2(R) is not fast enough to consistently detect this condition during a snapshot. It is recommended to use a DVOM set to the min/max recording mode. Connect the DVOM at the TPS connector (positive lead to TPS feedback signal pin and negative lead to TPS ground pin). Duplicate this condition by driving the vehicle. If the voltage dropout (less than 0.45 v) is recorded on the DVOM, replace the TPS sensor and re-evaluate the vehicle before continuing with other driveability or transmission diagnosis. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls Intermittent Chuggle/No DTC's Set > Page 1184 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1185 Throttle Position Sensor: Locations Left Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1186 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1187 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1188 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1189 Throttle Position (TP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1190 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Remove the 2 TP sensor screws. 4. Remove the TP sensor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1191 1. Install the TP sensor to the throttle body assembly. 2. Apply thread-locking compound GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the TP sensor screws. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 2 TP sensor screws. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Connect the TP sensor electrical connector. 5. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Lower Right Rear Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 1195 Vehicle Speed Sensor (VSS) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations Left Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1200 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1201 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1202 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1203 Mass Air Flow (MAF) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 1204 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. IMPORTANT: The mass air flow (MAF) sensor is attached to the throttle body assembly. 2. Disconnect the MAF sensor electrical connector (8). 3. Remove the MAF sensor screws (9). 4. Remove the MAF sensor (1). INSTALLATION PROCEDURE 1. Install the MAF sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF sensor screws (9). Tighten Tighten the screws to 3 N.m (27 lb in). 3. Connect the MAF sensor electrical connector (8). 4. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set Throttle Position Sensor: Customer Interest Engine Controls - Intermittent Chuggle/No DTC's Set Bulletin No.: 05-06-04-058 Date: September 07, 2005 TECHNICAL Subject: Intermittent Chuggle or Fishbite on Light Acceleration or at Highway Speeds with No Diagnostic Trouble Codes (DTCs) (Replace Throttle Position ( TPS) Sensor) Models: 1995-1999 Buick Riviera 1995-2004 Buick Regal 1995-2005 Buick LeSabre, Park Avenue 1997-2005 Buick Century 1995-2001 Chevrolet Lumina 1995-2002 Chevrolet Camaro 1995-2005 Chevrolet Monte Carlo 2000-2005 Chevrolet Impala 1995-1997 Oldsmobile Cutlass Supreme, Ninety Eight 1995-1999 Oldsmobile Eighty Eight 1998-2002 Oldsmobile Intrigue 1995-2002 Pontiac Firebird 1995-2003 Pontiac Grand Prix 1995-2005 Pontiac Bonneville with 3800 V6 Engine (VIN K - RPO L36) Condition Some customers may comment on an intermittent chuggle or fishbite on light acceleration or at steady-state highway speeds (typically 80-105 km/h [50-65 mph]) with no PCM DTCs set. This condition may lead the technician to suspect the TCC circuit or torque converter. Cause This condition may be caused by intermittent operation of the Throttle Position (TPS) Sensor. Correction In observed cases, the Tech 2(R) is not fast enough to consistently detect this condition during a snapshot. It is recommended to use a DVOM set to the min/max recording mode. Connect the DVOM at the TPS connector (positive lead to TPS feedback signal pin and negative lead to TPS ground pin). Duplicate this condition by driving the vehicle. If the voltage dropout (less than 0.45 v) is recorded on the DVOM, replace the TPS sensor and re-evaluate the vehicle before continuing with other driveability or transmission diagnosis. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set > Page 1213 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls Intermittent Chuggle/No DTC's Set Throttle Position Sensor: All Technical Service Bulletins Engine Controls - Intermittent Chuggle/No DTC's Set Bulletin No.: 05-06-04-058 Date: September 07, 2005 TECHNICAL Subject: Intermittent Chuggle or Fishbite on Light Acceleration or at Highway Speeds with No Diagnostic Trouble Codes (DTCs) (Replace Throttle Position ( TPS) Sensor) Models: 1995-1999 Buick Riviera 1995-2004 Buick Regal 1995-2005 Buick LeSabre, Park Avenue 1997-2005 Buick Century 1995-2001 Chevrolet Lumina 1995-2002 Chevrolet Camaro 1995-2005 Chevrolet Monte Carlo 2000-2005 Chevrolet Impala 1995-1997 Oldsmobile Cutlass Supreme, Ninety Eight 1995-1999 Oldsmobile Eighty Eight 1998-2002 Oldsmobile Intrigue 1995-2002 Pontiac Firebird 1995-2003 Pontiac Grand Prix 1995-2005 Pontiac Bonneville with 3800 V6 Engine (VIN K - RPO L36) Condition Some customers may comment on an intermittent chuggle or fishbite on light acceleration or at steady-state highway speeds (typically 80-105 km/h [50-65 mph]) with no PCM DTCs set. This condition may lead the technician to suspect the TCC circuit or torque converter. Cause This condition may be caused by intermittent operation of the Throttle Position (TPS) Sensor. Correction In observed cases, the Tech 2(R) is not fast enough to consistently detect this condition during a snapshot. It is recommended to use a DVOM set to the min/max recording mode. Connect the DVOM at the TPS connector (positive lead to TPS feedback signal pin and negative lead to TPS ground pin). Duplicate this condition by driving the vehicle. If the voltage dropout (less than 0.45 v) is recorded on the DVOM, replace the TPS sensor and re-evaluate the vehicle before continuing with other driveability or transmission diagnosis. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls Intermittent Chuggle/No DTC's Set > Page 1219 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1220 Throttle Position Sensor: Locations Left Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1221 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1222 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1223 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1224 Throttle Position (TP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1225 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Remove the 2 TP sensor screws. 4. Remove the TP sensor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 1226 1. Install the TP sensor to the throttle body assembly. 2. Apply thread-locking compound GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the TP sensor screws. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 2 TP sensor screws. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Connect the TP sensor electrical connector. 5. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1231 Right Middle Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1232 Camshaft Position (CMP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1233 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The camshaft position (CMP) sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor does not directly affect the operation of the ignition system. The CMP sensor information is used by the powertrain control module (PCM) to determine the position of the valve train relative to the CKP. By monitoring the CMP and CKP signals the PCM can accurately time the operation of the fuel injectors. The CMP sensor shares 12-volt and low reference circuits with the CKP sensor. The CMP signal circuit is input to the ICM. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1234 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the coolant recovery reservoir. 2. Remove the drive belt. 3. Disconnect the electrical connector (2) from the camshaft position sensor (1). 4. Remove the camshaft position sensor bolt. 5. Remove the camshaft position sensor from the engine front cover. INSTALLATION PROCEDURE 1. Install the camshaft position sensor to the engine front cover. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 1235 2. Install the camshaft position sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 3. Connect the electrical connector (2) to the camshaft position sensor (1). 4. Install the drive belt. 5. Install the coolant recovery reservoir. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1239 Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1240 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1241 Camshaft Position (CKP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1242 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSORS The crankshaft position (CKP) sensor has a 4-wire harness connector that plugs into the CKP sensor and connects to the ignition control module (ICM). The CKP sensor contains 2 hall-effect switches in 1 housing, and shares a magnet between the switches. The magnet and each hall-effect switch are separated by an air gap. A hall-effect switch is a solid state switching device that produces a digital ON/OFF pulse when a rotating element passes the sensor pick-up and interrupts the magnetic field of the sensor. The rotating element is called an interrupter ring or blade. There are two interrupter rings built into the crankshaft balancer. The outer ring and the outer switch provide the ICM with 18X signals or 18 identical pulses per crankshaft revolution. The inner ring and the inner switch provide the ICM with 3 pulses per revolution, each 1 of different duration. This is called the sync pulse. Each sync pulse represents a pair of companion cylinders. The ICM supplies a 12-volt and a low reference circuit to the CKP sensor, which is also shared by the camshaft position (CMP) sensor. The 18X reference pulses are passed from the CKP sensor to the ICM on the CKP sensor 1 signal circuit. The sync pulses are passed from the CKP sensor to the ICM on the CKP sensor 2 signal circuit. The ICM uses the 18X and sync pulses to determine the crankshaft position by counting how many ON-OFF 18X pulses occur during a sync pulse. With this dual interrupter ring arrangement the ICM can identify the correct pair of cylinders to fire within as little as 120 degrees of crankshaft rotation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1243 Crankshaft Position Sensor: Testing and Inspection CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The ignition control module (ICM) monitors the crankshaft position (CKP) sensor sync signal when the engine is cranking. The CKP sync signal is passed from the CKP sensor to the ICM on the CKP sensor 2 signal circuit. The CKP sync signal is used to determine the correct cylinder pair and initiate the ignition coil firing sequence. The 18X reference pulses are passed from the CKP sensor to the ICM on the CKP sensor 1 signal circuit. The 18X reference pulses are used for fuel injection and ignition control. After the ICM receives both signals, the ICM passes the 18X and 3X reference signals to the powertrain control module (PCM). The camshaft position sensor and the CKP sensor share a 12-volt reference and a low reference circuit. The CKP sensor consists of the following circuits: A 12-volt reference circuit - A low reference circuit - A CKP sensor 1 signal circuit - A CKP sensor 2 signal circuit TEST Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1244 Steps 4-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1245 Steps 8-14 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1246 Steps 15-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1247 Steps 21-26 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1248 Steps 27-28 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 1249 Steps 29-31 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 4.1. Accelerate to wide open throttle (WOT). 4.2. Release throttle when fuel cut-off occurs. 4.3. Observe fuel cut-off specification for applicable engine. 4.4. Engine should not accelerate beyond calibrated RPM value. 4.5. Release throttle immediately if value is exceeded. 4.6. Block drive wheels. 4.7. Set parking brake. 4.8. DO NOT apply brake pedal. 4.9. Cycle ignition from OFF to ON. 4.10. Apply and hold brake pedal. 4.11. Start and idle engine. 4.12. Turn A/C OFF. 4.13. Vehicle must remain in Park or Neutral. 4.14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure.The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - Crankshaft position (CKP) sensors activity - If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity - If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool and perform the following: IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 5.1. Accelerate to WOT. 5.2. Release when fuel cut-off occurs. 5.3. Test in progress. 6. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 . If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC. 7. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set Engine replacement - PCM replacement - A harmonic balancer replacement - Crankshaft replacement - CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1252 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the right splash shield cover. 4. Remove the crankshaft balancer. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the CKP sensor shield (1). 7. Remove the CKP sensor bolts. 8. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 1253 1. Position the CKP sensor to the block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolts. Tighten Tighten the bolts to 30 N.m (22 lb ft) 3. Install the CKP sensor shield (1). 4. Connect the CKP sensor electrical connector. 5. Install the crankshaft balancer. 6. Install the right splash shield cover. 7. Lower the vehicle. 8. Connect the negative battery cable. 9. Perform the Crankshaft Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder Replacement Removal Procedure Important: Perform the body control module (BCM) theft deterrent relearn procedure whenever you replace the ignition switch lock cylinder. 1. Disconnect the negative battery cable. 2. Remove the instrument panel (I/P) cluster trim plate. 3. Insert the key and turn the ignition lock cylinder to the ON/RUN position. 4. Using a small curved tool or an L-shaped hex wrench, depress and hold the detent on the ignition lock cylinder. Access the detent by placing the tool through the I/P opening to the right of the ignition switch. If you cannot locate the detent with the tool, lower the ignition switch away from the I/P. Refer to Ignition Switch Replacement. 5. Using the key as an aid, pull to remove the lock cylinder from the switch. 6. Remove the key from the lock cylinder. 7. If the cylinder does not rotate or is seized, follow the procedure in the ignition switch replacement. Refer to Ignition Switch Replacement. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 1258 1. Code the ignition lock cylinder, if necessary. Refer to Key and Lock Cylinder Coding in General Information. 2. Insert the key and turn the lock cylinder to the ON/RUN position. 3. Position the lock cylinder to the ignition switch. Press the cylinder into place. If you turned the key slightly while removing the lock cylinder, you may have to align the white colored ignition switch rotor (1) with the lock cylinder (2). You can rotate the ignition switch rotor (1) with your finger. 4. Turn the key to the OFF position and remove the key. 5. Install the I/P cluster trim plate. 6. Connect the negative battery cable. 7. If you installed a new lock cylinder, perform the BCM theft deterrent relearn procedure. Refer to Body Control Module (BCM) Programming/RPO Configuration in Body Control System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Lower Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1262 Rear Middle Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1263 Knock Sensor: Diagrams Knock Sensor (KS) 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1264 Knock Sensor (KS) 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1265 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This KS system uses one or two broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement Knock Sensor: Service and Repair Knock Sensor (KS) 1 Replacement KNOCK SENSOR (KS) 1 REPLACEMENT REMOVAL PROCEDURE CAUTION: Hot engine coolant may cause severe burns. Although the cooling system has been drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of the knock sensor. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Disconnect the knock sensor electrical connector (2). 4. Remove the knock sensor (1). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. 1. Install the knock sensor (1). Tighten Tighten the knock sensor to 19 N.m (14 lb ft). 2. Connect the knock sensor electrical connector (2). 3. Lower the vehicle. 4. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement > Page 1268 Knock Sensor: Service and Repair Knock Sensor (KS) 2 Replacement KNOCK SENSOR (KS) 2 REPLACEMENT REMOVAL PROCEDURE CAUTION: Hot engine coolant may cause severe burns. Although the cooling system has been drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of the knock sensor. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Remove the bolts (2) from the knock sensor heat shield (1). 4. Disconnect the knock sensor electrical connector (3) from the knock sensor. 5. Remove the knock sensor (4). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. 1. Install the knock sensor (4). Tighten Tighten the knock sensor to 19 N.m (14 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement > Page 1269 2. Install the knock sensor heat shield. Tighten Tighten the bolts to 60 N.m (44 lb ft). 3. Connect the knock sensor electrical connector. 4. Lower the vehicle. 5. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations SIR Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1274 Locations View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1275 Lower Left Of Passenger Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1276 Impact Sensor: Diagrams Inflatable Restraint Side Impact Sensor (SIS) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1277 Inflatable Restraint Front End Discriminating Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1278 Impact Sensor: Service Precautions CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 1279 Impact Sensor: Description and Operation INFLATABLE FRONT END SENSOR (EFS) The front end sensor also known as the electronic frontal sensor (EFS) is equipped on some vehicles to supplement the SIR system performance. The EFS is an electronic sensor (accelerometer) and is not part of the deployment loops, but instead provides an input to the SDM. The EFS can assist in determining the severity of some frontal collisions. The SDM contains a microprocessor which performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the frontal deployment loops, deploying the frontal air bags. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 2. Remove the radiator upper air baffle and deflector. 3. Remove the orange connector position assurance (CPA) (2) from the yellow sensor harness connector (3). 4. Disconnect the harness connector from the sensor (1). 5. Remove the sensor bolts (1). 6. Remove the sensor (2) from the upper radiator core support (3). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 1282 2. Connect the harness connector (3) to the sensor (1). 3. Install the orange CPA (2) into the yellow sensor harness connector (3). 4. Position the sensor (2) horizontally on the upper radiator core support (3). NOTE: Refer to Fastener Notice in Service Precautions. 5. Point the arrow on the sensor toward the front of the vehicle. 6. Install the sensor bolts (1). Tighten Tighten the bolts to 9 N.m (80 lb in). 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. 8. Install the radiator upper air baffle and deflector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 1283 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 2 (Impala)SIR Disabling and Enabling Zone 2 (Monte Carlo). CAUTION: Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 2. Remove the center pillar lower trim. 3. Remove the connector position assurance (CPA) from the yellow 2-way harness connector on the inflatable restraint side impact sensor. 4. Disconnect the wiring harness connector from the side impact sensor. 5. Loosen the 2 fasteners (2) on the side impact sensor. 6. Remove the side impact sensor (1) from the center pillar (3). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Install the side impact sensor (1) to the center pillar (3). 3. Tighten the 2 fasteners (2) on the side impact sensor (1). 4. Connect the yellow 2-way harness connector on the side impact sensor. 5. Install the CPA to the yellow 2-way connector on the side impact sensor and tighten using only hand tools. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 1284 Tighten Tighten the fasteners to 10 N.m (89 lb in). 6. Install the center pillar lower trim. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 2 (Impala)SIR Disabling and Enabling Zone 2 (Monte Carlo). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Right Side Of Driver Seat Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 1288 Seat Belt Switch-left Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder Replacement Removal Procedure Important: Perform the body control module (BCM) theft deterrent relearn procedure whenever you replace the ignition switch lock cylinder. 1. Disconnect the negative battery cable. 2. Remove the instrument panel (I/P) cluster trim plate. 3. Insert the key and turn the ignition lock cylinder to the ON/RUN position. 4. Using a small curved tool or an L-shaped hex wrench, depress and hold the detent on the ignition lock cylinder. Access the detent by placing the tool through the I/P opening to the right of the ignition switch. If you cannot locate the detent with the tool, lower the ignition switch away from the I/P. Refer to Ignition Switch Replacement. 5. Using the key as an aid, pull to remove the lock cylinder from the switch. 6. Remove the key from the lock cylinder. 7. If the cylinder does not rotate or is seized, follow the procedure in the ignition switch replacement. Refer to Ignition Switch Replacement. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 1298 1. Code the ignition lock cylinder, if necessary. Refer to Key and Lock Cylinder Coding in General Information. 2. Insert the key and turn the lock cylinder to the ON/RUN position. 3. Position the lock cylinder to the ignition switch. Press the cylinder into place. If you turned the key slightly while removing the lock cylinder, you may have to align the white colored ignition switch rotor (1) with the lock cylinder (2). You can rotate the ignition switch rotor (1) with your finger. 4. Turn the key to the OFF position and remove the key. 5. Install the I/P cluster trim plate. 6. Connect the negative battery cable. 7. If you installed a new lock cylinder, perform the BCM theft deterrent relearn procedure. Refer to Body Control Module (BCM) Programming/RPO Configuration in Body Control System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1305 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams TCC Brake Switch Wiring Harness Side C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1314 Automatic Transmission Fluid Pressure Manual Valve Position Switch Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1315 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the transaxle wiring harness. 3. Remove the control valve body bolts (375, 379, 381) that mount the fluid pressure manual valve position switch to the control valve body (300). Important: When removing the TFP switch handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 4. Carefully remove the fluid pressure manual valve position switch (395) 5. Inspect the fluid pressure manual valve position switch (395) for the following conditions ^ Damaged electrical connector terminals ^ Damaged seals ^ Damaged switch membranes ^ Debris on the switch membranes Installation Procedure Important: When installing the TFP switch handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 1. Carefully install the fluid pressure manual valve position switch (395). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the control valve body bolts (375, 379, 381) that mount the TFP switch to the control valve body (300). ^ Tighten the control valve body bolt (375) to 12 Nm (106 inch lbs.). ^ Tighten the control valve body bolt (379) to 16 Nm (106 inch lbs.). ^ Tighten the control valve body bolt (381) to 8 Nm (70 inch lbs.). 3. Connect the transaxle wiring harness. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 1316 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1320 Input Speed Sensor Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1321 Transmission Speed Sensor: Service and Repair Input Speed Sensor Replacement Removal Procedure 1. Remove the case side cover 2. Disconnect the input speed sensor electrical connector. 3. Remove the input speed sensor retaining clip (441). 4. Remove the input speed sensor (440). 5. Inspect the input speed sensor (440) for the following conditions: ^ Damaged or missing magnet ^ Damaged housing ^ Bent or missing electrical terminals ^ Damaged speed sensor clip (441) Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 1322 1. Install the input speed sensor (440). 2. Install the input speed sensor retaining clip (441). 3. Connect the input speed sensor electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 1326 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 1327 Transmission Fluid Temperature Sensor Connector Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement Transmission Temperature Sensor/Switch: Service and Repair Thermo Element Replacement Thermo Element Replacement Tools Required ^ J 34094-A Thermo Element Height Gage Removal Procedure 1. Raise and support the vehicle. 2. Remove the oil pan. 3. Remove the thermo element pins (120, 123) and the washers. 4. Remove the thermo element (121) and the thermo element plate (122). Installation Procedure 1. Use the J 34094-A to set the middle thermo pin (123). 2. Install the new thermo element plate (122). 3. Install the pin (120) and the washer. 4. Use the J 34094-A to set the height of the pin and the washer furthest from the accumulator. 5. Use the J 34094-A to set the height of the second pin (120) and the washer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement > Page 1330 6. Install the thermo element (121) between the two pins (120). The V in the thermo element (121) must contact the thermo element plate (122). 7. Install the oil pan. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement > Page 1331 Transmission Temperature Sensor/Switch: Service and Repair Fluid Temperature Sensor Replacement Fluid Temperature Sensor Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the wiring harness assembly tram the fluid temperature sensor (391) 3. Remove the fluid temperature sensor (391). Installation Procedure 1. install the fluid temperature sensor (391). 2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Interior - Power Window Switch Removal Precaution Power Window Switch: Technical Service Bulletins Interior - Power Window Switch Removal Precaution Bulletin No.: 04-08-64-007 Date: April 22, 2004 INFORMATION Subject: Proper Removal of Power Window Switch to Avoid Damage to Door Trim Pad or Power Window Switch - Remove Trim Pad First Models: 2004 Chevrolet Malibu Maxx To replace the left front door power window switch, the door panel must be removed. There is a retaining clip at the front of the switch and two retaining tabs on the side of the switch. The clip and tabs must be released from the back side of the door panel. Trying to pry the switch out of the door trim panel without releasing the tabs and clip from the back will result in damage to either the door trim panel, the switch bezel or both. may result. When removing the door trim panel, be careful not to pull on the wire to the trunk release switch, or damage to the switch. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Page 1337 Power Window Switch: Locations Front Of Driver Door Trim (Windows) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Page 1338 Front Door Trim-Typical Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Page 1339 Front Of Right Rear Door Trim, Left Rear Similar Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1342 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1343 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1344 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1345 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1346 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1347 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1348 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1349 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1350 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1351 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1352 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1353 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1354 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1355 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1356 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1357 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1358 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1359 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1360 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1361 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1362 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1363 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1364 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1365 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1366 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1367 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1368 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1369 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1370 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1371 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1372 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1373 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1374 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1375 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1376 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1377 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1378 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1379 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1380 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1381 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1382 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1383 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1384 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1385 Power Window Switch: Connector Views Window Switch-Driver, C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1386 Window Switch-Driver, C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1387 Window Switch-Driver, C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1388 Window Switch-Front Passenger Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1389 Window Switch-Front Passenger Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1390 Window Switch-LR Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1391 Window Switch-LR Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1392 Window Switch-RR Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement Power Window Switch: Service and Repair Power Window Switch Replacement POWER WINDOW SWITCH REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Remove the front door pull cup screws (1) and pull cup from the front door trim panel. Armrest Pull Cup Replacement (Impala)Armrest Pull Cup Replacement (Monte Carlo). 2. Disconnect the electrical connectors from the front door power window control switch. 3. Remove the front door window control switch using a small, flat-bladed tool at the side of the switch. INSTALLATION PROCEDURE 1. Install the front door power window control switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connector to the power window control switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement > Page 1395 3. Install the front door pull cup and screws (1) to the front door trim panel. Armrest Pull Cup Replacement (Impala)Armrest Pull Cup Replacement (Monte Carlo). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement > Page 1396 Power Window Switch: Service and Repair Power Window Switch Replacement (Impala) Power Window Switch Replacement (Impala) Removal Procedure 1. Remove the front door pull cup screws (1) and pull cup from the front door trim panel. Armrest Pull Cup Replacement (Impala) Armrest Pull Cup Replacement (Monte Carlo). 2. Disconnect the electrical connectors from the front door power window control switch. 3. Remove the front door window control switch using a small, flat-bladed tool at the side of the switch. Installation Procedure 1. Install the front door power window control switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connector to the power window control switch. 3. Install the front door pull cup and screws (1) to the front door trim panel. Armrest Pull Cup Replacement (Impala) Armrest Pull Cup Replacement (Monte Carlo). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement > Page 1397 Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door POWER WINDOW SWITCH REPLACEMENT - REAR DOOR (IMPALA) REMOVAL PROCEDURE 1. Remove the rear door pull cup from the rear door trim panel. 2. Disconnect the electrical connectors from the power window control switch. 3. Remove the rear door window control switch from the pull cup using a small, flat-bladed tool at the side of the power window control switch to release the power window control switch retainer. 4. Remove the power window control switch from the rear door pull cup. INSTALLATION PROCEDURE 1. Install the rear door power window control switch to the rear door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the rear door power window control switch. 3. Install the rear door pull cup to the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement > Page 1398 Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door (Impala) Power Window Switch Replacement - Rear Door (Impala) Removal Procedure 1. Remove the rear door pull cup from the rear door trim panel. 2. Disconnect the electrical connectors from the power window control switch. 3. Remove the rear door window control switch from the pull cup using a small, flat-bladed tool at the side of the power window control switch to release the power window control switch retainer. 4. Remove the power window control switch from the rear door pull cup. Installation Procedure 1. Install the rear door power window control switch to the rear door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the rear door power window control switch. 3. Install the rear door pull cup to the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Right Front Of Vehicle Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1403 Windshield Washer Fluid Level Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 1404 Washer Fluid Level Switch: Service and Repair WASHER SOLVENT CONTAINER LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Drain the washer solvent from the washer solvent container. 2. Remove the right front fender liner. 3. Disconnect the washer solvent container level sensor electrical connector. 4. Using a small flat-bladed tool, remove the washer solvent level sensor from the washer solvent container. 5. Using a small flat-bladed tool, remove the seal from the washer solvent container. INSTALLATION PROCEDURE 1. Position the seal to the washer solvent container, pressing in until fully seated. 2. Position the washer solvent level sensor to the washer solvent container, pressing in until fully seated. 3. Connect the washer solvent level sensor electrical connector. 4. Install the right front fender liner. 5. Fill the washer solvent container with washer solvent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Windshield Washer Switch: Locations Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 1408 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 1412 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1418 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1419 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1420 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1421 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1422 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1423 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 1424 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications Trim Height Specifications Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications > Page 1427 Alignment: Specifications Wheel Alignment Specifications WHEEL ALIGNMENT SPECIFICATIONS FRONT SUSPENSION CAMBER Service Allowable ................................................................................................................................ ................................................ -0.28 to -1.28° Service Preferred ........................................................ ...................................................................................................................................... -0.78° CASTER Service Allowable ................................................................................................................................ ................................................. 2.70 to 3.70° Service Preferred ......................................................... ....................................................................................................................... Not Adjustable STEERING ANGLE Service Allowable ................................................................................................................................ ............................................... -3.50 to +3.50° Service Preferred ........................................................ ............................................................................................................................................ 0° TOE - TOTAL Service Allowable ................................................................................................................................ ............................................... -0.10 to +0.30° Service Preferred ........................................................ ....................................................................................................................................... 0.10° REAR SUSPENSION CAMBER Service Allowable ................................................................................................................................ ................................................... -1.0 to +0.0° Service Preferred ........................................................ ....................................................................................................................................... -0.50° THRUST ANGLE Service Allowable ................................................................................................................................ ............................................... -0.15 to +0.15° Service Preferred ........................................................ ............................................................................................................................................ 0° TOE - TOTAL Service Allowable ................................................................................................................................ ............................................... -0.10 to +0.30° Service Preferred ........................................................ ....................................................................................................................................... 0.10° Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Trim Height Specifications > Page 1428 Fastener Tightening Specifications Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1429 Alignment: Description and Operation Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1430 Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Lead/pull is the deviation of the vehicle from a straight path, on a level road, without hand pressure on the steering wheel. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Uneven brake adjustment ^ Wheel alignment The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1431 Torque Steer Description A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the other direction during deceleration. The following factors may cause torque steer to be more apparent on a particular vehicle: ^ A slightly smaller diameter tire on the right front increases a right torque lead. Inspect the front tires for differences in the brand, the construction, ^ or the size. If the tires appear to be similar, change the front tires from side-to-side and retest the vehicle. Tire and wheel assemblies have the most significant effect on torque steer correction. ^ A large difference in the right and left front tire pressure ^ Left-to-right differences in the front view axle angle may cause significant steering pull in a vehicle. The pull will be to the side with the most downward sloping axle from the differential to the wheels. Axles typically slope downward from the differential. The slope of the transaxle pan to level ground may be used as an indication of bias axle angles. The side with the higher transaxle pan, shown on the left side of the illustration, has the most downward sloping axle angle. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure Alignment: Service and Repair Trim Height Inspection Procedure Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: 1. Set the tire pressures to the pressure shown on the certification label. 2. Check the fuel level. Add additional weight if necessary to simulate a full tank. 3. Make sure the rear compartment is empty except for the spare tire. 4. Make sure the vehicle is on a level surface, such as an alignment rack. 5. Close the doors. 6. Close the hood. 7. All dimensions are measured vertical to the ground. Trim heights should be within 13 mm (0.5 in.) to be considered correct. Z Height Measurement The Z height dimension measurement determines the proper ride height for the front end of the vehicle. There is no adjustment procedure. Repair may require replacement of suspension components. 1. Lift the front bumper of the vehicle up about 38 mm (1.5 in.). 2. Gently remove your hands. Let the vehicle settle. 3. Repeat this operation for a total of 3 times. 4. Measure from the pivot bolt center line down to the lower corner of the lower ball joint in order to obtain the Z height measurement. 5. Push the front bumper of the vehicle down about 38 mm (1.5 in.). 6. Gently remove your hands. 7. Allow the vehicle to settle into position. 8. Repeat the jouncing operation 2 more times for a total of 3 times. 9. Measure the Z dimension. 10. The true Z height dimension number is the average of the high and the low measurements. D Height Measurement The D height dimension measurement determines the proper rear end ride height. There is no adjustment procedure. Repair may require replacement of suspension components. 1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 in.). 2. Gently remove your hands. Allow the vehicle to settle into position. 3. Repeat the jouncing operation 2 more times for a total of 3 times. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 1434 4. The D height is measured from a point 30 mm (1.1 in.) outboard of the rear brake hose bracket bolt centerline to the bolt centerline of the trailing arm to the knuckle attachment. 5. Push the rear bumper downward to 38 mm (1.5 in.). 6. Gently remove your hands. Allow the vehicle to settle into position. 7. Repeat the jouncing operation 2 more times for a total of 3 times. 8. Measure the D height dimension. 9. The true D height dimension number is the average of the high and the low measurements. 10. If these measurements are out of specifications, inspect for the following conditions: ^ Improper weight distribution ^ Collision damage ^ Worn or damaged suspension components Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 1435 Alignment: Service and Repair Measuring Wheel Alignment Measuring Wheel Alignment Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. Notice: Refer to Fastener Notice in Service Precautions. ^ Inspect the steering gear for looseness at the frame. ^ Inspect the struts/shock absorbers for wear, leaks and any noticeable noises. ^ Inspect the vehicle trim height. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 1436 Alignment: Service and Repair Rear Wheel Alignment Rear Camber Adjustment Removal Procedure 1. Raise the vehicle and provide suitable support. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the strut from the vehicle. 4. Place the strut in a vise and file the upper strut-to-knuckle hole lateral - oblong. Compare the appearance of the holes before filing (2) with l after filing (3). Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the strut to the vehicle. ^ Tighten the strut-to-knuckle bolts as far as to allow movement of the knuckle. 2. Install the tire and wheel assemblies. 3. Adjust the camber (1). ^ Tighten the strut-to-knuckle bolts to 122 Nm (90 ft. lbs.). 4. Lower the vehicle. Rear Toe Adjustment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 1437 1. Loosen the hex nuts at the rear wheel spindle rod - rear. 2. Turn the adjusting nut to change the toe angle. 3. Adjust the toe to the proper setting. Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the hex nuts on the rear wheel spindle rod - rear. ^ Tighten the rear wheel spindle rod ends hex nuts to 50 Nm (37 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 1438 Alignment: Service and Repair Front Wheel Alignment Front Camber Adjustment Removal Procedure 1. Raise the vehicle and provide suitable support. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies from the front and the rear axles. 3. Remove the strut from the vehicle. 4. Place the strut in a vise and file the hole lateral -oblong. Compare the appearance of the holes before filing (2) with after filing (3). 5. File the lower strut-to-knuckle attaching hole for a front camber adjustment. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the strut to the vehicle. ^ Tighten the strut-to-knuckle nuts as far as to allow movement of the knuckle. 2. Install the tire and wheel assemblies. 3. Adjust the camber (1). ^ Tighten the strut-to-knuckle nuts to 120 Nm (89 ft. lbs.). 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 1439 Front Toe Adjustment 1. Remove the small seal clamp from the inner tie rod boot. 2. Position the steering wheel in the straight ahead position. 3. Loosen the hex nut on the tie rod (2). Turn the tie rod shaft (1) in order to obtain the proper toe angle. 4. Confirm the number of threads showing on each tie rod end is nearly equal. Notice: Refer to Fastener Notice in Service Precautions. 5. Confirm that the tie rod ends (3) are square before you tighten the lock nuts (2). ^ Tighten the hex nuts at the tie rod ends to 68 Nm (50 ft. lbs.). Important: Ensure the seals do not twist. 6. Install the seal clamps. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Page 1440 Special Tools and Equipment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 364-405 kPa (53-59 psi) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable.A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Remove the fuel injector sight shield. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Install the J 34730-1A to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1447 3. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gage. 7. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container. Open the bleed valve in order to bleed the fuel system pressure. 2. Place a shop towel under the fuel pressure gage in order to catch any remaining fuel spillage. 3. Remove the fuel pressure gage from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1448 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST DESCRIPTION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1449 Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1450 Steps 4-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1451 Steps 8-9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1452 Steps 10-11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1453 Steps 12-15 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1454 Steps 16-17 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1455 Steps 18-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 1456 Steps 21-25 The numbers below refer to the step numbers on the diagnostic table. 2. This step verifies that the fuel pump is operating. 4. This step tests for an internal fuel leak. If the fuel pressure decreases during this test, an internal loss of pressure is indicated. 6. This step tests the fuel pressure regulator. The fuel pressure regulator is controlled by engine vacuum. With engine vacuum applied, the pressure should decrease by the specified value. 9. This step inspects the fuel pressure regulator for a fuel leak from the vacuum port. If fuel leaks from the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator. 10. This step tests for a loss of fuel pressure between the shut-off adapter on the fuel feed pipe and the fuel pump. 11. This step tests for a leaking fuel injector, or fuel pressure regulator. If the fuel pressure remains constant during this test, the fuel injectors are not leaking fuel. 14. This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, a restriction in the fuel return pipe is indicated. 16. This step determines if the fuel pressure regulator, or the fuel pump, is the cause of the low fuel pressure. If the pressure rises above the specified value, the fuel pump is OK. 18. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Inspect all fuel pump electrical circuits thoroughly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER INTAKE DUCT REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector (3). 2. Remove the IAT sensor with a twisting and pulling motion. 3. Loosen the air cleaner intake duct clamp. 4. Remove the air cleaner intake duct from the air cleaner cover. 5. Remove the air cleaner intake duct from the throttle body. INSTALLATION PROCEDURE 1. Install the air cleaner intake duct to the throttle body. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the air cleaner intake duct to the air cleaner cover. Tighten Tighten the air cleaner duct clamp to 2 N.m (18 lb in). 3. Install the IAT sensor. 4. Connect the IAT sensor electrical connector (3). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 1472 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 1478 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception Antenna Control Module: All Technical Service Bulletins Audio System - Static/Poor Radio Reception Bulletin No.: 05-08-44-008A Date: June 17, 2005 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Static, Poor and/or No AM/FM Radio Reception In Police Package Equipped Vehicles (Replace Radio Antenna Module) Models: 2004-2005 Chevrolet Impala Built After VIN Breakpoint 49302036 with Police Package (RPO 9C1) Supercede: This bulletin is being revised to include Diagnostic and Repair Information, remove an RPO code and include a VIN breakpoint. Please discard Corporate Bulletin Number 05-08-44-008 (Section 08 - Body and Accessories). Condition Some customers may comment that certain police package vehicles equipped with radio communication equipment may experience poor AM/FM radio reception, no radio reception and/or static through the radio system. Cause Police package vehicles radio communication equipment may overload the radio AM/FM radio antenna module. Diagnosis To ensure the radio antenna module is the cause of the poor reception, refer to Radio Poor Reception (SI Document ID # 782713). Correction If diagnosis leads to a suspect radio antenna module, replace the Radio Antenna Module. Refer to Antenna Module Replacement (SI Document ID # 1515377). Dealer Action Contact customers that were told they would be notified when this repair became available. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception > Page 1484 Parts Parts will be available for dealer ordering on June 20, 2005. Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception > Page 1490 Parts Parts will be available for dealer ordering on June 20, 2005. Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1491 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner intake duct . 2. Unclip the 2 air cleaner cover retaining clamps. 3. Remove the air cleaner housing cover (5). 4. Remove the air filter element (6). 5. Inspect the air cleaner housing cover (5), the seal assembly, and the air cleaner intake duct for damage. If a problem is found, replace as necessary. INSTALLATION PROCEDURE 1. Install the air filter element (6). 2. Install the air cleaner housing cover (5) and clip the housing cover retaining clamps. 3. Install the air cleaner intake duct. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable.A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Remove the fuel injector sight shield. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Install the J 34730-1A to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1497 3. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gage. 7. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container. Open the bleed valve in order to bleed the fuel system pressure. 2. Place a shop towel under the fuel pressure gage in order to catch any remaining fuel spillage. 3. Remove the fuel pressure gage from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1498 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage RELIEF PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the fuel injector sight shield. 3. Loosen the fuel filler cap to relieve tank vapor pressure. 4. Connect the J 34730-1A to the fuel pressure connection. Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gage in order to avoid spillage. 5. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 6. Drain any fuel remaining in the fuel pressure gage into an approved container. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Refer to the list below for items to be inspected. 1. Inspect for correct routing of the spark plug wires. Improper routing may cause cross-firing. 2. Inspect each wire for any signs of cracks or splits in the wire. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal both the wire and the component connected to the wire should be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 1502 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT TOOLS REQUIRED J 38491 Spark Plug Boot Removal Tool REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Remove the spark plug wires (2, 4, 6) from the spark plugs at the rear of the engine using the following steps: 2.1. Note the position of the spark plug wires before removing the wires. 2.2. Twist the spark plug boot 1/2 turn before removing the boot. 2.3. Gently pry the heat shield up from spark plugs using the J 38491. 2.4. Remove the spark plug wire from the spark plugs at rear of the engine. 3. Remove the spark plug wires (1, 3, 5) from the spark plugs at the front of the engine using the following steps: 3.1. Note the position of the spark plug wires before removing the wires. 3.2. Twist the spark plug boot 1/2 turn before removing the boot. 3.3. Gently pry the heat shield up from spark plugs using the J 38491. 3.4. Remove the spark plug wires form the spark plugs at the front of the engine. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 1503 4. Remove the spark plug wires from the ignition coils. 5. Remove the spark plug wire retaining clips from the rear, front and top of the engine. 6. Remove the spark plug wires from the engine. 7. When replacing the spark plug wires transfer any of the following: - Boot heat shields - Spark plug wire conduit - Spark plug wire retaining clips INSTALLATION PROCEDURE 1. Position the spark plug wires to the engine. 2. Install the spark plug wire retaining clips from the rear, front and top of the engine. 3. Install the spark plug wires to the ignition coil in the proper position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 1504 4. Install the spark plug wires (1, 3, 5) to the spark plugs in the proper position at the front of the engine. 5. Install the spark plug wires (2, 4, 6) to the spark plugs in the proper position at the rear of the engine. 6. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark Plug Gap ................................................................................................................................... ..................................................... 0.060 in. (1.52 mm) Spark Plug Torque ........................................ ........................................................................................................................................ 11.0 lb. ft. (15.0 Nm) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1508 Spark Plug: Application and ID SPARK PLUG AC Delco P/N ...................................................................................................................................... .................................................................. 41-921 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1509 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION SPARK PLUG USAGE - Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. - Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1510 - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications . An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. - A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION - Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures - Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element Incorrect combustion - Reduced ignition system voltage output - Weak coils Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1511 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 1512 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wires from the spark plugs. 2. Remove the spark plugs from the engine. INSTALLATION PROCEDURE 1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to the gap specifications. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the spark plugs to the engine. Tighten If installing the spark plugs to a new cylinder tighten the plugs to 27N.m (20 lb ft). - If installing the spark plugs to an existing cylinder tighten the plugs to 15N.m(11 lb ft). 1. Connect the spark plug wires to the spark plugs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications No cylinder reading should be less than 689 kPa (100 psi) The lowest reading should not be less than 70 percent of the highest reading. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 1516 Compression Check: Testing and Inspection Engine Compression Test - Tools Required J 38722 Compression Tester A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket. 1. Run the engine until it reaches normal operating temperature. The battery must be at or near full charge. 2. Turn the engine OFF. Important: Remove the Powertrain Control Module (PCM) and the ignition fuses from the I/P fuse block. 3. Disable the ignition. 4. Disable the fuel systems. 5. Remove the spark plugs from all the cylinders. 6. Remove the air duct from the throttle body. 7. Block the throttle plate in the open position. 8. Measure the engine compression, using the following procedure: 8.1. Firmly install J 38722 to the spark plug hole. 8.2. Have an assistant crank the engine through at least four compression strokes in the testing cylinder. 8.3. Check and record the readings on J 38722 at each stroke. 8.4. Disconnect J 38722. 8.5. Repeat the compression test for each cylinder. 9. Record the compression readings from all of the cylinders. - The lowest reading should not be less than 70 percent of the highest reading. - No cylinder reading should be less than 689 kPa (100 psi). 10. The following are examples of the possible measurements: - When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. - When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, or if the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. - When the compression is low on the first stroke and does not build up in the following strokes, or the addition of oil does not affect the compression, the valves may be the cause. - When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause. 11. Remove the block from the throttle plate. 12. Install the air duct to the throttle body. 13. Install the spark plugs. 14. Install the Powertrain Control Module (PCM) fuse. 15. Install the ignition fuse to the I/P fuse block. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1521 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1522 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 1523 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1524 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1525 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: The drive belt - The drive belt tensioner - The crankshaft balancer pulley - The accessory drive components: The power steering pump - The generator - The A/C compressor - The water pump The drive belt system uses one belt. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belt is made of different types of rubbers-chloroprene or EPDM-and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt or the pulleys. It may be necessary to spray a small amount of water on the drive belt in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1528 Steps 1-15 Drive Belt Chirping Diagnosis Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1529 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mix-positioning the drive belt one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Steps 1-6 Drive Belt Excessive Wear Diagnosis Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1530 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1531 Drive Belt Falls Off Diagnosis Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1532 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, complete the diagnostic table, and if the noise is only heard when the drive belt is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Steps 1-8 Drive Belt Rumbling Diagnosis Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1533 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt or the pulleys. It may be necessary to spray a small amount of water on the drive belt in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1534 Steps 1-15 Drive Belt Chirping Diagnosis Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1535 The numbers below refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mix-positioning the drive belt one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Steps 1-6 Drive Belt Excessive Wear Diagnosis Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1536 Drive Belt Falls Off Diagnosis Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, complete the diagnostic table, and if the noise is only heard when the drive belt is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1537 Steps 1-8 Drive Belt Rumbling Diagnosis Drive Belt Squeal Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the squeal noise is the drive belt or an accessory drive component. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. This test is to verify that an accessory drive component does not have a seized bearing. With the belt remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory drive components with the engine operating by varying the load on the components to verify that the components operate properly. 5. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 6. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 7. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1538 component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. Steps 1-9 Drive Belt Squeal Diagnosis Drive Belt Vibration Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belts or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The drive belt may cause a vibration. While the drive belt is removed this is the best time to inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1539 10. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Steps 1-11 Drive Belt Vibration Diagnosis Drive Belt Whine Drive Belt Whine Diagnosis Diagnostic Aids The drive belt will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operating to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing. Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This test is to verify that the noise is being caused by the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper inspection and replacement procedure. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 1540 Steps 1-5 Drive Belt Whine Diagnosis Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1541 Drive Belt: Service and Repair version 1.0 This procedure is not covered in the cartool: Drive Belt Replacement (L32) Removal Procedure 1. Rotate the drive belt tensioner using a 15-mm box end wrench on the pulley nut. 2. Remove the drive belt. Installation Procedure Important: After the new drive belt is installed, make sure that the mark on the drive belt tensioner is within range, as indicated on the tensioner housing. 1. Lift or rotate the drive belt tensioner using a 15-mm box end wrench on the pulley nut. 2. Install the drive belt. 3. Make sure the drive belt is properly routed. 4. Make sure the drive belt tensioner is operating properly. *********************************************************************** Minimum specs I could not find: 3.4L No Flywheel Sequence Camshaft Bearing Cap torque and sequence Valve Clearance Oil pan sequence Oil pump sequence Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Drive Belt > Component Information > Testing and Inspection > Page 1542 throttle body sequence 3.8L No Flywheel Sequence Camshaft Bearing Cap torque and sequence Valve Clearance Oil pan sequence Oil pump sequence throttle body sequence Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER INTAKE DUCT REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector (3). 2. Remove the IAT sensor with a twisting and pulling motion. 3. Loosen the air cleaner intake duct clamp. 4. Remove the air cleaner intake duct from the air cleaner cover. 5. Remove the air cleaner intake duct from the throttle body. INSTALLATION PROCEDURE 1. Install the air cleaner intake duct to the throttle body. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the air cleaner intake duct to the air cleaner cover. Tighten Tighten the air cleaner duct clamp to 2 N.m (18 lb in). 3. Install the IAT sensor. 4. Connect the IAT sensor electrical connector (3). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T Shift/Driveability Concerns/MIL ON > Page 1556 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 1562 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 1563 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner intake duct . 2. Unclip the 2 air cleaner cover retaining clamps. 3. Remove the air cleaner housing cover (5). 4. Remove the air filter element (6). 5. Inspect the air cleaner housing cover (5), the seal assembly, and the air cleaner intake duct for damage. If a problem is found, replace as necessary. INSTALLATION PROCEDURE 1. Install the air filter element (6). 2. Install the air cleaner housing cover (5) and clip the housing cover retaining clamps. 3. Install the air cleaner intake duct. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations Cabin Air Filter: Locations PASSENGER COMPARTMENT AIR FILTER The Passenger Compartment Air Filter is located underneath the hood just below the windshield wiper arm on the passenger's side of the vehicle, underneath the air inlet grille. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations > Page 1567 Cabin Air Filter: Service and Repair PASSENGER COMPARTMENT AIR FILTER REPLACEMENT REMOVAL PROCEDURE 1. Position the windshield wipers in the UP position, by keying the ignition OFF when the wiper reach the desired position. 2. Raise the hood. 3. Remove the rear hood seal. 4. Remove the washer hose from the right air inlet grill panel and position aside. 5. Remove the two push pin retainers from the right air inlet grill panel. IMPORTANT: Do not remove the third push pin retainer from the right air inlet grill panel 6. Position the left side of the right air inlet grill panel on to the windshield. 7. Remove the passenger compartment air filter. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Cabin Air Filter > Component Information > Locations > Page 1568 1. Install the passenger compartment air filter. 2. Install the left side of the right air inlet grill panel in to position. 3. Install the push pin retainers to the right air inlet grill panel. 4. Position the washer hose in to the right air inlet grill panel clips. 5. Install the rear hood seal. 6. Close the hood. 7. Return the windshield wipers to the PARK position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair Oil Filter and Seal Replacement Removal Procedure 1. Remove the oil pan (24) and the gasket (25). 2. Remove the filter (100). Remove the lip ring seal (101) pressed into the case only if replacement is necessary. 3. Inspect the oil pan and the filter for the following foreign material: ^ metal particles ^ clutch facing material ^ rubber particles ^ engine coolant 4. Determine the source of the contamination if foreign material is evident. 5. Correct the source of the contamination. Installation Procedure 1. If removed, install a new seal (101). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair > Page 1572 2. Install the filter (100). 3. Install the gasket (25) and the oil pan (24). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable.A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Remove the fuel injector sight shield. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Install the J 34730-1A to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1578 3. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gage. 7. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container. Open the bleed valve in order to bleed the fuel system pressure. 2. Place a shop towel under the fuel pressure gage in order to catch any remaining fuel spillage. 3. Remove the fuel pressure gage from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 1579 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage RELIEF PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the fuel injector sight shield. 3. Loosen the fuel filler cap to relieve tank vapor pressure. 4. Connect the J 34730-1A to the fuel pressure connection. Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gage in order to avoid spillage. 5. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 6. Drain any fuel remaining in the fuel pressure gage into an approved container. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 1583 Fuel Pump Pickup Filter: Service and Repair FUEL STRAINER REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Remove the fuel sender assembly. 2. Note the strainer (3) position for future reference. 3. Support the reservoir with one hand. Grasp the strainer with the other hand. 4. Use a screwdriver to pry the strainer ferrule off the reservoir. 5. Discard the strainer. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 1584 1. Install the new strainer (4) to the reservoir. 2. Support the reservoir with one hand. Grasp the strainer with the other hand. Twist the strainer into position. 3. Install the fuel sender assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1589 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. 2. Position the oil drain pan under the engine oil drain plug. 3. Remove the engine oil drain plug. 4. Clean and inspect the engine oil drain plug, repair or replace if necessary. 5. Clean and inspect the engine oil drain plug sealing surface on the oil pan, repair or replace oil pan if necessary. 6. Remove the oil filter. 7. Clean and inspect the oil filter sealing area on the oil filter adapter, repair or replace if necessary. Installation Procedure 1. Lightly oil the replacement oil filter gasket with clean oil and install the new oil filter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 1590 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the new oil filter. - Tighten the new oil filter to 3/4 to 1 full turn, after the oil filter gasket contacts the oil filter mounting surface. 3. Install the engine oil pan drain plug. - Tighten the plug to 30 Nm (22 ft. lbs.). 4. Remove the oil drain pan. 5. Lower the vehicle. 6. Fill the engine with new engine oil. 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the oil indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, readjust the oil level by adding or draining the engine oil. 16. Check for oil leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement Coolant Line/Hose: Service and Repair Thermostat Bypass Pipes Replacement Thermostat Bypass Pipes Replacement - Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Partially drain the cooling system. 2. Remove the air cleaner intake duct. 3. Remove the LH engine mount strut. 4. Remove the spark plugs wires from the left side spark plugs. 5. Use the J 38185 to reposition the radiator inlet hose clamp from the water outlet housing. 6. Remove the radiator inlet hose from the water outlet housing. 7. Remove the heater outlet hose (2) from the thermostat bypass pipe. 8. Remove the throttle body inlet (3) and outlet (4) hoses from the thermostat bypass pipe. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 1596 9. Remove the thermostat bypass pipe nut. 10. Remove the thermostat bypass pipe hose and clamp from the thermostat bypass pipe. 11. Remove the thermostat bypass pipe bolt. 12. Remove the thermostat bypass pipe. Installation Procedure 1. Install the thermostat bypass pipe. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the thermostat bypass pipe bolt. - Tighten the bolt to 11 Nm (98 inch lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 1597 3. Install the thermostat bypass pipe hose and clamp to the thermostat bypass pipe. 4. Install the thermostat bypass pipe nut. - Tighten the nut to 25 Nm (18 ft. lbs.). 5. Install the heater outlet hose (2) and the clamp to the thermostat bypass pipe. 6. Install the throttle body inlet (3) and outlet (4) hoses and the clamps to the thermostat bypass pipe. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 1598 7. Install the radiator inlet hose to the water outlet housing. 8. Use the J 38185 to reposition and install the radiator inlet hose clamp to the water outlet housing. 9. Install the spark plugs wires to the left side spark plugs. 10. Install the LH engine mount strut. 11. Install the air cleaner intake duct. 12. Fill the cooling system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 1599 Coolant Line/Hose: Service and Repair Throttle Body Heater Hose Replacement - Inlet Throttle Body Heater Hose Replacement - Inlet Removal Procedure 1. Remove the air cleaner intake duct. 2. Partially drain the cooling system. 3. Remove the throttle body inlet hose clamp and the hose (3) from the coolant pipe. 4. Remove the throttle body inlet hose clamp and the hose (3) from the throttle body and the vehicle. Installation Procedure 1. Install the throttle body inlet hose (3) and the hose clamp to the throttle body. 2. Install the throttle body inlet hose (3) and the hose clamp to the coolant pipe. 3. Install the air cleaner intake duct. 4. Fill the cooling system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 1600 Coolant Line/Hose: Service and Repair Throttle Body Heater Hose Replacement - Outlet Throttle Body Heater Hose Replacement - Outlet Removal Procedure 1. Remove the air cleaner intake duct. 2. Partially drain the cooling system. 3. Remove the throttle body outlet hose clamp and the hose (4) from the coolant pipe. 4. Remove the throttle body outlet hose clamp and the hose (4) from the throttle body and the vehicle. Installation Procedure 1. Install the throttle body outlet hose (4) and the hose clamp to the throttle body. 2. Install the throttle body outlet hose (4) and the hose clamp to the coolant pipe. 3. Install the air cleaner intake duct. 4. Fill the cooling system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet Heater Hose: Service and Repair Heater Hose Replacement - Inlet HEATER HOSE REPLACEMENT - INLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the fuel injector sight shield. 3. Use J 38185 in order to position aside the heater hose inlet clamp at the pipe adapter. 4. Disconnect the heater inlet hose from the pipe adapter. 5. Use J 38185 in order to position aside the heater core inlet hose clamp. 6. Disconnect the heater inlet hose from the heater core. 7. Remove the heater inlet hose from the support bracket. INSTALLATION PROCEDURE 1. Install the heater inlet hose to the support bracket. 2. Connect the heater inlet hose to the heater core. 3. Use J 38185 in order to secure the heater core hose inlet clamp. 4. Connect the heater inlet hose to the pipe adapter. 5. Use J 38185 in order to secure the heater hose inlet clamp. 6. Install the fuel injector sight shield. 7. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 1605 Heater Hose: Service and Repair Heater Hose Replacement - Outlet HEATER HOSE REPLACEMENT - OUTLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the fuel injector sight shield. 3. Use J 38185 in order to position aside the heater hose outlet clamp at the pipe adapter. 4. Disconnect the heater outlet hose from the pipe adapter. 5. Use J 38185 in order to position aside the heater core outlet hose clamp. 6. Disconnect the heater outlet hose from the heater core. 7. Remove the heater outlet hose from the support bracket. INSTALLATION PROCEDURE 1. Install the heater outlet hose to the support bracket. 2. Connect the heater outlet hose to the heater core. 3. Use J 38185 in order to secure the heater core hose outlet clamp. 4. Connect the heater outlet hose to the pipe adapter. 5. Use J 38185 in order to secure the heater hose outlet clamp. 6. Install the fuel injector sight shield. 7. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 1606 Heater Hose: Service and Repair Heater Pipe Replacement - Inlet HEATER PIPE ADAPTER REPLACEMENT - INLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the fuel injector sight shield. 3. Use J 38185 in order to position aside the heater hose clamp. 4. Disconnect the heater inlet hose from the heater pipe adapter. 5. Remove the heater pipe adapter mounting bolt. 6. Remove the heater pipe adapter. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 1607 1. Lubricate the O-ring seal with Dex-Cool antifreeze. 2. Install the heater pipe adapter. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the heater inlet pipe adapter mounting bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Connect the inlet hose to the heater pipe adapter. 5. Use J 38185 in order to secure the heater core hose clamp. 6. Install the fuel injector sight shield. 7. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 1608 Heater Hose: Service and Repair Heater Pipe Adapter Replacement - Outlet HEATER PIPE ADAPTER REPLACEMENT - OUTLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the fuel injector sight shield. 3. Use J 38185 in order to position aside the heater hose clamp. 4. Remove the heater outlet hose from the heater pipe adapter. 5. Remove the heater pipe adapter mounting bolt. 6. Remove the heater pipe adapter. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 1609 1. Lubricate the O-ring seal with Dex-Cool antifreeze. 2. Install the heater pipe adapter. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the heater outlet pipe adapter mounting bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the heater outlet hose to the pipe adapter. 5. Use J 38185 in order to secure the heater core hose clamp. 6. Install the fuel injector sight shield. 7. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector Hose/Line HVAC: Service and Repair A/C Line/Tube Connector A/C LINE/TUBE CONNECTOR REMOVAL/REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Locate the A/C coupling assembly's locking tab access slots (1). IMPORTANT: When separating the A/C coupling assembly, apply light pressure between the two halves of the coupling to prevent the locking tabs from reengaging. 3. Carefully insert a small flat bladed screwdriver into the first locking tab access slot and gently lift the locking tab to release the lock. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector > Page 1614 4. Carefully insert a small flat bladed screwdriver into the second locking tab access slot and gently lift the locking tab to release the lock. 5. Open and remove the A/C coupling assembly from the A/C refrigerant component. INSTALLATION PROCEDURE IMPORTANT: Inspect the A/C coupling assembly locking tabs for damage or wear. Replace the A/C coupler assembly if any conditions exist. 1. Install the A/C coupling assembly to the A/C refrigerant component. IMPORTANT: Ensure that the A/C coupling assembly is latched securely to the A/C refrigerant component. 2. Close the A/C coupling assembly. 3. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 4. Leak test the fittings of the component using J 39400-A. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector > Page 1615 Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement COMPRESSOR HOSE ASSEMBLY REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner assembly. 3. Remove the A/C compressor hose nut from the condenser. 4. Disconnect the A/C compressor hose from the condenser. 5. Remove the A/C compressor hose nut from the compressor hose block to evaporator tube. 6. Remove the A/C compressor hose from the evaporator tube. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector > Page 1616 7. Remove the lower air deflector. 8. Remove the A/C compressor hose nut from the A/C compressor. 9. Remove the A/C compressor hose from the A/C compressor. 10. Remove and discard all sealing washers. INSTALLATION PROCEDURE 1. Install new sealing washers onto the A/C compressor hose assembly. 2. Install the A/C compressor hose to the A/C compressor. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the A/C compressor hose nut to the A/C compressor. Tighten Tighten the nut to 27 N.m (20 lb ft). 4. Install the lower air deflector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector > Page 1617 5. Install new seals washers to the A/C compressor hose assembly and evaporator tube. 6. Install the A/C compressor hose to the evaporator tube. 7. Install the A/C compressor hose to evaporator tube nut. Tighten Tighten the nut to 16 N.m (12 lb ft). 8. Install the A/C compressor hose to the condenser. 9. Install the A/C compressor hose nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 10. Install the air cleaner assembly. 11. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 12. Leak test the fittings of the component using J 39400-A. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector > Page 1618 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement EVAPORATOR TUBE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner assembly. 3. Remove the bolt from the ground wire below the air cleaner assembly. 4. Remove the brake pressure modulator valve bracket. 5. Disconnect the electrical connector from the brake fluid level sensor. 6. Remove the oxygen sensor connector from the fuel injector sight shield rear bracket. 7. Remove the master cylinder mounting nuts. 8. Remove the master cylinder from the brake booster and position aside. 9. Remove the engine vacuum line from the brake booster. 10. Remove the A/C line coupling from the evaporator tube to receiver dehydrator tube (1). 11. Remove the receiver dehydrator mounting bolt (2). 12. Disconnect the receiver dehydrator from the evaporator tube. 13. Remove the block fitting nut that secures the evaporator tube to the A/C compressor hose assembly. 14. Disconnect the evaporator tube from the A/C compressor hose assembly. 15. Remove the block fitting nut (1) that secures the evaporator tube to the TXV. 16. Remove the heater hoses from the support bracket and position aside. 17. Remove the transmission shift cable from the retainer above the heater hoses and position the cable aside. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector > Page 1619 18. Disconnect the evaporator tube from the TXV. 19. Remove the evaporator tube from the support clip (1) on the left fender rail. 20. Remove the transaxle fluid filler tube. 21. Disconnect the wire harness electrical connector from the A/C pressure sensor. 22. Disconnect the wire harness electrical connector C101 near the top of the left shock tower. 23. Remove the evaporator tube from the vehicle. 24. Remove the A/C pressure sensor. 25. Remove and discard the O-ring seals and seal washers. INSTALLATION PROCEDURE 1. Replace the O-ring seal on the receiver dehydrator and A/C pressure sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the A/C pressure sensor to the evaporator line. Tighten Tighten the sensor to 4.7 N.m (41 lb in). 3. Replace the seal washers on the evaporator tube. 4. Install the evaporator tube to the vehicle. 5. Install the transaxle fluid filler tube. 6. Connect the evaporator tube to the support clip (1) on the left fender rail. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector > Page 1620 7. Connect the evaporator tube to the TXV. 8. Install the evaporator tube to TXV nut (1). Tighten Tighten the nut to 27 N.m (20 lb ft). 9. Install the oxygen sensor connector to the fuel injector sight shield rear bracket. 10. Install the heater hoses to the support bracket. 11. Install the transmission shift cable to the retainer above the heater hoses. 12. Connect the receiver dehydrator to the evaporator tube. 13. Install the A/C line coupling to the evaporator tube and receiver dehydrator tube (1). 14. Install the receiver dehydrator mounting bolt (2). Tighten Tighten the bolt to 4 N.m (36 lb in). 15. Connect the A/C compressor hose assembly to the evaporator tube. 16. Install the A/C compressor hose assembly to evaporator tube block fitting nut. Tighten Tighten the nut to 16 N.m (12 lb ft). 17. Install the brake pressure modulator valve bracket. 18. Install the master cylinder to the brake booster. 19. Install the nuts to the master cylinder. Tighten Tighten the nuts to 25 N.m (18 lb ft). 20. Connect the electrical connector to the brake fluid level sensor. 21. Install the engine vacuum line to the brake booster. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector > Page 1621 22. Connect the wire harness electrical connector C101 near the top of the left shock tower. 23. Install the bolt to the ground wire below the air cleaner assembly. Tighten Tighten the bolt to 10 N.m (89 in lb). 24. Install the air cleaner assembly. 25. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 26. Leak test the fittings of the component using J 39400-A. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise Power Steering Line/Hose: Customer Interest Steering - Steering Gear Leaks/Moan or Groan Noise Bulletin No.: 05-02-32-007D Date: March 29, 2007 ENGINEERING INFORMATION Subject: EI05119 - Power Steering Gear Leak, Moan, Groan or Whine Noise (Diagnose and Repair as Necessary) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2004-2007 Chevrolet Impala, Monte Carlo 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to provide additional leak and noise diagnosis information. Please discard Corporate Bulletin Number 05-02-32-007C (Section 02 - Steering). Condition Some customers may comment on a power steering gear leak or that the gear appears to be leaking. Additionally, the customer may come into the dealership indicating they were told by an aftermarket service facility that the steering gear was leaking because the power steering reservoir was low on fluid and the gear showed an oil residue. Some customers may also comment on a power steering noise during steering maneuvers or while driving. Correction Inspect and diagnose the power steering system before any repairs are attempted using the procedure listed below. Because the power steering reservoir on 3800 V6-equipped vehicles is located behind and below the rear cylinder head, the fluid level may not be getting checked and/or topped off similar to other vehicles which have a reservoir that is located on the upper portion of the engine. This condition could be more prevalent with vehicles serviced at non-GM dealerships. Determine if the power steering system is full of oil. Adjust the fluid in the reservoir to the proper level. The lower fluid level could be the result of a variation in the original system fill. Plus, over time and mileage, the system purges any remaining air. Additionally, as the hoses expand and contract, the fluid level may drop as measured within the reservoir. Don't assume there is an external fluid leak just because the fluid level in the reservoir is down to the Add mark. Restart the engine and see if the noise goes away after turning the steering wheel lock to lock a few times. This will correct most, if not all, the vehicles with a noise condition. If the customer was told their was a power steering fluid leak by an aftermarket service facility because the power steering reservoir needed fluid and they saw oil residue on the power steering gear, then carefully inspect the gear and surrounding area for oil residue. Below are some causes as to why oil residue may be present. Oil residue on the body of the steering gear usually on the pinion area (left side) of the gear or on the convoluted boots. This condition could be caused by a small amount of oil that can drip out when the shipping plugs are removed from the gear, just prior to the installation of the P/S pressure and return lines being connected at the assembly plants. Gears should not be replaced for this condition. Oil residue on or near the pinion adjuster nut plug. During the gear assembly process the supplier uses grease to lubricate the pinion adjuster plug threads. In cases where a lot of grease was used on the adjuster plug threads, some grease can ooze out around the threads and when mixed with moisture and road grime, it can appear as though the plug is leaking. In some cases the heat generated from the exhaust system will start to liquefy some of the grease and cause it to run. Gears should not be replaced for this condition. Oil residue inside the convoluted boots. When the steering gear is assembled into the housing, grease is applied to the gear teeth. In some cases, if there is a lot of grease used, it will squeeze out of the gear teeth, soften and run down and collect in the bottom of the convolutes. This may have the appearance of a thick oil, especially in hot climates. Some technicians have seen this liquefied grease and thought is was power steering fluid. Gears should not be replaced for this condition. If the customer indicates that they have seen what they think was a leak, resembling oil residue, on their garage floor or driveway, or the technician sees Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise > Page 1630 drops of oil leaking, carefully inspect the power steering hydraulic system. The inspection should be performed while the engine is running and the steering wheel is rotated from lock to lock. If a leak is observed, then repair the source of the leak. If the noise is not the result of low power steering fluid, provide a complete description of when the noise happens and what type of noise it is; i.e. squeal, pop, clunk, tick, continuous rubbing, etc. If it is a pop or clunk noise, make sure you inspect the convoluted boots to determine if the inner tie rod is rubbing the boots. Replace the boot or boots only for this condition. If the noise is a clunk or pop noise and it's not the inner tie rod rubbing the convoluted boots, make sure to inspect the intermediate shaft for the slip stick condition. This should be done prior to replacing any steering gears. If amber/yellow tinted glasses and the "pen light" style of black light are used, the lithium in the grease will show up in greenish/yellow similar to the greenish/yellow dye used by many dealerships to test for leaks. Always use the black light recommended by GM Tools and clear glasses to inspect for dye in fluid leaks. If the source of the leak cannot be found by visual inspection, add dye, P/N 88861206 (in Canada, use P/N 88861259), and inspect the system using Black Light (J 28428-E or J 42220). The number of vehicles that will require a complete inspection using dye will be minimal based on the inspection of numerous steering gears returned for testing where the complaint was fluid leak and no leaks could be reproduced. If a steering gear is replaced because a leak was discovered using the dye test method, make sure the repair order has a description of where the leak was discovered. If the steering gear is replaced for a noise concern, make sure a complete description of the diagnosis appears on the repair order as described in Step 5 above. Steering gears replaced under warranty will continue to be on parts return and regional feedbacks will be processed on any gears which the customer complaint cannot be verified. Over 90% of all steering gears inspected have little or no explanation of the condition, the technician's diagnosis or reason for replacing the gears and/or did not have any indication that dye was used to find a leak. Parts Information Warranty Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise Power Steering Line/Hose: All Technical Service Bulletins Steering - Steering Gear Leaks/Moan or Groan Noise Bulletin No.: 05-02-32-007D Date: March 29, 2007 ENGINEERING INFORMATION Subject: EI05119 - Power Steering Gear Leak, Moan, Groan or Whine Noise (Diagnose and Repair as Necessary) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2004-2007 Chevrolet Impala, Monte Carlo 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to provide additional leak and noise diagnosis information. Please discard Corporate Bulletin Number 05-02-32-007C (Section 02 - Steering). Condition Some customers may comment on a power steering gear leak or that the gear appears to be leaking. Additionally, the customer may come into the dealership indicating they were told by an aftermarket service facility that the steering gear was leaking because the power steering reservoir was low on fluid and the gear showed an oil residue. Some customers may also comment on a power steering noise during steering maneuvers or while driving. Correction Inspect and diagnose the power steering system before any repairs are attempted using the procedure listed below. Because the power steering reservoir on 3800 V6-equipped vehicles is located behind and below the rear cylinder head, the fluid level may not be getting checked and/or topped off similar to other vehicles which have a reservoir that is located on the upper portion of the engine. This condition could be more prevalent with vehicles serviced at non-GM dealerships. Determine if the power steering system is full of oil. Adjust the fluid in the reservoir to the proper level. The lower fluid level could be the result of a variation in the original system fill. Plus, over time and mileage, the system purges any remaining air. Additionally, as the hoses expand and contract, the fluid level may drop as measured within the reservoir. Don't assume there is an external fluid leak just because the fluid level in the reservoir is down to the Add mark. Restart the engine and see if the noise goes away after turning the steering wheel lock to lock a few times. This will correct most, if not all, the vehicles with a noise condition. If the customer was told their was a power steering fluid leak by an aftermarket service facility because the power steering reservoir needed fluid and they saw oil residue on the power steering gear, then carefully inspect the gear and surrounding area for oil residue. Below are some causes as to why oil residue may be present. Oil residue on the body of the steering gear usually on the pinion area (left side) of the gear or on the convoluted boots. This condition could be caused by a small amount of oil that can drip out when the shipping plugs are removed from the gear, just prior to the installation of the P/S pressure and return lines being connected at the assembly plants. Gears should not be replaced for this condition. Oil residue on or near the pinion adjuster nut plug. During the gear assembly process the supplier uses grease to lubricate the pinion adjuster plug threads. In cases where a lot of grease was used on the adjuster plug threads, some grease can ooze out around the threads and when mixed with moisture and road grime, it can appear as though the plug is leaking. In some cases the heat generated from the exhaust system will start to liquefy some of the grease and cause it to run. Gears should not be replaced for this condition. Oil residue inside the convoluted boots. When the steering gear is assembled into the housing, grease is applied to the gear teeth. In some cases, if there is a lot of grease used, it will squeeze out of the gear teeth, soften and run down and collect in the bottom of the convolutes. This may have the appearance of a thick oil, especially in hot climates. Some technicians have seen this liquefied grease and thought is was power steering fluid. Gears should not be replaced for this condition. If the customer indicates that they have seen what they think was a leak, resembling oil residue, on their garage floor or driveway, or the technician sees Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise > Page 1636 drops of oil leaking, carefully inspect the power steering hydraulic system. The inspection should be performed while the engine is running and the steering wheel is rotated from lock to lock. If a leak is observed, then repair the source of the leak. If the noise is not the result of low power steering fluid, provide a complete description of when the noise happens and what type of noise it is; i.e. squeal, pop, clunk, tick, continuous rubbing, etc. If it is a pop or clunk noise, make sure you inspect the convoluted boots to determine if the inner tie rod is rubbing the boots. Replace the boot or boots only for this condition. If the noise is a clunk or pop noise and it's not the inner tie rod rubbing the convoluted boots, make sure to inspect the intermediate shaft for the slip stick condition. This should be done prior to replacing any steering gears. If amber/yellow tinted glasses and the "pen light" style of black light are used, the lithium in the grease will show up in greenish/yellow similar to the greenish/yellow dye used by many dealerships to test for leaks. Always use the black light recommended by GM Tools and clear glasses to inspect for dye in fluid leaks. If the source of the leak cannot be found by visual inspection, add dye, P/N 88861206 (in Canada, use P/N 88861259), and inspect the system using Black Light (J 28428-E or J 42220). The number of vehicles that will require a complete inspection using dye will be minimal based on the inspection of numerous steering gears returned for testing where the complaint was fluid leak and no leaks could be reproduced. If a steering gear is replaced because a leak was discovered using the dye test method, make sure the repair order has a description of where the leak was discovered. If the steering gear is replaced for a noise concern, make sure a complete description of the diagnosis appears on the repair order as described in Step 5 above. Steering gears replaced under warranty will continue to be on parts return and regional feedbacks will be processed on any gears which the customer complaint cannot be verified. Over 90% of all steering gears inspected have little or no explanation of the condition, the technician's diagnosis or reason for replacing the gears and/or did not have any indication that dye was used to find a leak. Parts Information Warranty Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1642 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1643 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1644 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1650 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1651 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Line/Hose: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 1652 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Pressure Hose Power Steering Line/Hose: Service and Repair Pressure Hose Power Steering Pressure Pipe/Hose Replacement (3.8L) Removal Procedure 1. Place a drain pan under the vehicle. 2. Remove the accessory drive belt. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the tire and wheel assembly. 5. The power steering pressure hose is the lower hose at the power steering gear. Remove the power steering pressure hose from the power steering gear. 6. Remove the power steering pressure hose from the power steering pump. 7. Remove the power steering pressure hose from the clamps on the power steering gear. 8. Remove the power steering pressure hose from the vehicle. Installation Procedure 1. Install the power steering pressure hose to the vehicle. 2. Install the power steering pressure hose to the clamps on the power steering gear. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering pressure hose to the power steering pump. ^ Tighten the fitting to 27 Nm (20 ft. lbs.). 4. Install the power steering pressure hose to the power steering gear. ^ Tighten the pressure hose fitting to 27 Nm (20 ft. lbs.). 5. Install the tire and wheel assembly. 6. Remove the drain pan from under the vehicle. 7. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Pressure Hose > Page 1655 8. Install the accessory drive belt. 9. Fill the power steering system with power steering fluid. 10. Bleed the power steering system. 11. Inspect the power steering system for leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Pressure Hose > Page 1656 Power Steering Line/Hose: Service and Repair Return Hose Power Steering Return Hose Replacement (3.8L) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the power steering return hose (2) from the power steering gear (1). 4. Remove the return hose (2) from the clips on the power steering gear. 5. Remove the return hose (1) from the power steering pump. 6. Remove the return hose (1) from the hose retainers (3) on the cradle (4). 7. Disconnect the clips and the electrical harnesses from the return hose (1). 8. Remove the return hose (1) from the vehicle. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Pressure Hose > Page 1657 1. Install the return hose (1) to the vehicle. 2. Connect the clips and the electrical harnesses to the return hose (1). 3. Install the return hose (1) to the hose retainers (3) on the cradle (4). 4. Install the return hose (1) to the power steering pump. 5. Install the return hose (2) to the clips on the power steering gear. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the return hose (1) to the power steering gear (1). ^ Tighten the fitting to 27 Nm (20 ft. lbs.). 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Fill the power steering fluid reservoir. 10. Bleed the power steering system. 11. Inspect the power steering system for leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Pressure Hose > Page 1658 Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Replacement Power Steering Cooler Pipe/Hose Replacement Removal Procedure 1. Remove the engine mount struts from the engine. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. 4. Place a drain pan under the vehicle. Notice: The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly. 5. Remove the intermediate steering shaft from the power steering gear stub shaft. 6. Use a utility stand in order to support the frame. 7. Remove the frame bolts from the rear of the frame. Notice: Do not lower the rear of the frame too far as damage to the engine components nearest to the cowl may result. 8. Use the utility stand in order to lower the rear of the frame to gain access. 9. Remove the power steering return hose from the power steering pump to the power steering cooler pipe. 10. Remove the power steering return line from the power steering gear. 11. Remove the power steering return line from the clamp on the power steering gear. 12. Remove the power steering cooler pipe retaining clips. 13. Remove the power steering cooler pipe from the vehicle. Installation Procedure 1. Install the power steering cooler pipe to the vehicle. 2. Install the power steering cooler pipe retaining clips. 3. Install the power steering return line to the power steering gear. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and Repair > Pressure Hose > Page 1659 4. Install the power steering return line to the clamp on the power steering gear. 5. Install the power steering return hose from the power steering pump to the power steering cooler pipe. 6. Use the utility stand in order to raise the frame. 7. Install NEW frame bolts to the rear of the frame. 8. Install the intermediate steering shaft to the power steering gear stub shaft. 9. Install the tire and wheel assembly. 10. Remove the drain pan from under the vehicle. 11. Lower the vehicle. 12. Install the engine mount struts to the engine. 13. Fill the power steering fluid reservoir. 14. Bleed the power steering system. 15. Inspect the power steering system for leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet Radiator Hose: Service and Repair Inlet Radiator Hose Replacement - Inlet (3.8L) - Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Partially drain the cooling system. 2. Remove the left diagonal brace. 3. Use the J 38185 in order to reposition the hose clamp from the radiator. 4. Remove the radiator inlet hose from the radiator. 5. Use the J 38185 in order to reposition the hose clamp from the water outlet housing. 6. Remove the radiator inlet hose from the water outlet housing and the vehicle. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet > Page 1664 1. Align the marks on the hose. Install the radiator inlet hose to the water outlet housing. 2. Use the J 38185 in order to reposition and install the hose clamp to the water outlet housing. 3. Install the radiator inlet hose to the radiator. 4. Use the J 38185 in order to reposition and install the hose clamp to the radiator. 5. Install the left diagonal brace. 6. Fill the cooling system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet > Page 1665 Radiator Hose: Service and Repair Outlet Radiator Hose Replacement - Outlet (3.8L) - Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Remove the lower radiator air deflector. 3. Use the J 38185 in order to reposition the hose clamp from the radiator. 4. Remove the radiator outlet hose (3) from the radiator (2). 5. Lower the vehicle. 6. Use J 38185 in order to reposition the hose clamp from the water pump housing. 7. Remove the radiator outlet hose from the water pump housing. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Service and Repair > Inlet > Page 1666 1. Align the marks on the hose. Install the radiator outlet hose to the water pump housing. 2. Use J 38185 in order to reposition the hose clamp to the water pump housing. 3. Raise and support the vehicle. 4. Install the radiator outlet hose (3) to the radiator (2). 5. Use J 38185 in order to reposition the hose clamp to the radiator. 6. Install the lower radiator air deflector. 7. Fill the cooling system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Information not supplied by the manufacturer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 1672 Brake Fluid: Fluid Type Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1677 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1678 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1679 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 1680 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Cooling System ....................................................................................................................... ............................................... 11.0 liters (11.7 quarts) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1683 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: ^ Give freezing protection down to -34°F (-37°C). ^ Give boiling protection up to 265°F (129°C). ^ Protect against rust and corrosion. ^ Help keep the proper engine temperature. ^ Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1688 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1689 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 1690 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Pan Removal ........................................................................................................ ............................................................................................. 7.0L (7.4 Qt) Overhaul ........................... .............................................................................................................................................................. ................. 9.5L (10.0 Qt) Dry .............................................................................................................. .................................................................................................. 12.7L (13.4 Qt) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 1693 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1698 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 1699 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil ............................................................................................................................................ ............................................................. 4.3L (4.5 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 1702 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Above -18° C (0° F) ......................................... ......................................................................................................................................... 5W-30 or 10W-30 Below -20° C (-4° F) ............................................................................................................... .................................................... 5W-30 synthetic or 0W-30 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1703 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. 2. Position the oil drain pan under the engine oil drain plug. 3. Remove the engine oil drain plug. 4. Clean and inspect the engine oil drain plug, repair or replace if necessary. 5. Clean and inspect the engine oil drain plug sealing surface on the oil pan, repair or replace oil pan if necessary. 6. Remove the oil filter. 7. Clean and inspect the oil filter sealing area on the oil filter adapter, repair or replace if necessary. Installation Procedure 1. Lightly oil the replacement oil filter gasket with clean oil and install the new oil filter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1704 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the new oil filter. - Tighten the new oil filter to 3/4 to 1 full turn, after the oil filter gasket contacts the oil filter mounting surface. 3. Install the engine oil pan drain plug. - Tighten the plug to 30 Nm (22 ft. lbs.). 4. Remove the oil drain pan. 5. Lower the vehicle. 6. Fill the engine with new engine oil. 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the oil indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, readjust the oil level by adding or draining the engine oil. 16. Check for oil leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise Power Steering Fluid: Customer Interest Steering - Steering Gear Leaks/Moan or Groan Noise Bulletin No.: 05-02-32-007D Date: March 29, 2007 ENGINEERING INFORMATION Subject: EI05119 - Power Steering Gear Leak, Moan, Groan or Whine Noise (Diagnose and Repair as Necessary) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2004-2007 Chevrolet Impala, Monte Carlo 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to provide additional leak and noise diagnosis information. Please discard Corporate Bulletin Number 05-02-32-007C (Section 02 - Steering). Condition Some customers may comment on a power steering gear leak or that the gear appears to be leaking. Additionally, the customer may come into the dealership indicating they were told by an aftermarket service facility that the steering gear was leaking because the power steering reservoir was low on fluid and the gear showed an oil residue. Some customers may also comment on a power steering noise during steering maneuvers or while driving. Correction Inspect and diagnose the power steering system before any repairs are attempted using the procedure listed below. Because the power steering reservoir on 3800 V6-equipped vehicles is located behind and below the rear cylinder head, the fluid level may not be getting checked and/or topped off similar to other vehicles which have a reservoir that is located on the upper portion of the engine. This condition could be more prevalent with vehicles serviced at non-GM dealerships. Determine if the power steering system is full of oil. Adjust the fluid in the reservoir to the proper level. The lower fluid level could be the result of a variation in the original system fill. Plus, over time and mileage, the system purges any remaining air. Additionally, as the hoses expand and contract, the fluid level may drop as measured within the reservoir. Don't assume there is an external fluid leak just because the fluid level in the reservoir is down to the Add mark. Restart the engine and see if the noise goes away after turning the steering wheel lock to lock a few times. This will correct most, if not all, the vehicles with a noise condition. If the customer was told their was a power steering fluid leak by an aftermarket service facility because the power steering reservoir needed fluid and they saw oil residue on the power steering gear, then carefully inspect the gear and surrounding area for oil residue. Below are some causes as to why oil residue may be present. Oil residue on the body of the steering gear usually on the pinion area (left side) of the gear or on the convoluted boots. This condition could be caused by a small amount of oil that can drip out when the shipping plugs are removed from the gear, just prior to the installation of the P/S pressure and return lines being connected at the assembly plants. Gears should not be replaced for this condition. Oil residue on or near the pinion adjuster nut plug. During the gear assembly process the supplier uses grease to lubricate the pinion adjuster plug threads. In cases where a lot of grease was used on the adjuster plug threads, some grease can ooze out around the threads and when mixed with moisture and road grime, it can appear as though the plug is leaking. In some cases the heat generated from the exhaust system will start to liquefy some of the grease and cause it to run. Gears should not be replaced for this condition. Oil residue inside the convoluted boots. When the steering gear is assembled into the housing, grease is applied to the gear teeth. In some cases, if there is a lot of grease used, it will squeeze out of the gear teeth, soften and run down and collect in the bottom of the convolutes. This may have the appearance of a thick oil, especially in hot climates. Some technicians have seen this liquefied grease and thought is was power steering fluid. Gears should not be replaced for this condition. If the customer indicates that they have seen what they think was a leak, resembling oil residue, on their garage floor or driveway, or the technician sees Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise > Page 1713 drops of oil leaking, carefully inspect the power steering hydraulic system. The inspection should be performed while the engine is running and the steering wheel is rotated from lock to lock. If a leak is observed, then repair the source of the leak. If the noise is not the result of low power steering fluid, provide a complete description of when the noise happens and what type of noise it is; i.e. squeal, pop, clunk, tick, continuous rubbing, etc. If it is a pop or clunk noise, make sure you inspect the convoluted boots to determine if the inner tie rod is rubbing the boots. Replace the boot or boots only for this condition. If the noise is a clunk or pop noise and it's not the inner tie rod rubbing the convoluted boots, make sure to inspect the intermediate shaft for the slip stick condition. This should be done prior to replacing any steering gears. If amber/yellow tinted glasses and the "pen light" style of black light are used, the lithium in the grease will show up in greenish/yellow similar to the greenish/yellow dye used by many dealerships to test for leaks. Always use the black light recommended by GM Tools and clear glasses to inspect for dye in fluid leaks. If the source of the leak cannot be found by visual inspection, add dye, P/N 88861206 (in Canada, use P/N 88861259), and inspect the system using Black Light (J 28428-E or J 42220). The number of vehicles that will require a complete inspection using dye will be minimal based on the inspection of numerous steering gears returned for testing where the complaint was fluid leak and no leaks could be reproduced. If a steering gear is replaced because a leak was discovered using the dye test method, make sure the repair order has a description of where the leak was discovered. If the steering gear is replaced for a noise concern, make sure a complete description of the diagnosis appears on the repair order as described in Step 5 above. Steering gears replaced under warranty will continue to be on parts return and regional feedbacks will be processed on any gears which the customer complaint cannot be verified. Over 90% of all steering gears inspected have little or no explanation of the condition, the technician's diagnosis or reason for replacing the gears and/or did not have any indication that dye was used to find a leak. Parts Information Warranty Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 06-02-32-009B > Nov > 08 > Steering - Noise Diagnostics TSB References Power Steering Fluid: All Technical Service Bulletins Steering - Noise Diagnostics TSB References INFORMATION Bulletin No.: 06-02-32-009B Date: November 19, 2008 Subject: Overview of Steering System Noises Models: 2001-2004 Buick Regal 2001-2005 Buick Century 2005-2007 Buick Allure (Canada Only), LaCrosse 2000-2006 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 1998-2002 Oldsmobile Intrigue 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to remove reference to Corporate Bulletin Number 01-02-32-001 from the table below. Please discard Corporate Bulletin Number 06-02-32-009A (Section 02 - Steering). The purpose of this bulletin is to provide a quick reference for dealers to aid in locating the correct service bulletin for several different steering system noise concerns. Many customer concerns with the steering system involve specific symptoms (noises heard). Once the customer concern has been verified, the table above may help identify the correct bulletin to reference. If other symptoms are present, or if diagnosis indicates another cause not found in any of the three service bulletins, refer to SI to diagnose the repair customer concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise Power Steering Fluid: All Technical Service Bulletins Steering - Steering Gear Leaks/Moan or Groan Noise Bulletin No.: 05-02-32-007D Date: March 29, 2007 ENGINEERING INFORMATION Subject: EI05119 - Power Steering Gear Leak, Moan, Groan or Whine Noise (Diagnose and Repair as Necessary) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2004-2007 Chevrolet Impala, Monte Carlo 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to provide additional leak and noise diagnosis information. Please discard Corporate Bulletin Number 05-02-32-007C (Section 02 - Steering). Condition Some customers may comment on a power steering gear leak or that the gear appears to be leaking. Additionally, the customer may come into the dealership indicating they were told by an aftermarket service facility that the steering gear was leaking because the power steering reservoir was low on fluid and the gear showed an oil residue. Some customers may also comment on a power steering noise during steering maneuvers or while driving. Correction Inspect and diagnose the power steering system before any repairs are attempted using the procedure listed below. Because the power steering reservoir on 3800 V6-equipped vehicles is located behind and below the rear cylinder head, the fluid level may not be getting checked and/or topped off similar to other vehicles which have a reservoir that is located on the upper portion of the engine. This condition could be more prevalent with vehicles serviced at non-GM dealerships. Determine if the power steering system is full of oil. Adjust the fluid in the reservoir to the proper level. The lower fluid level could be the result of a variation in the original system fill. Plus, over time and mileage, the system purges any remaining air. Additionally, as the hoses expand and contract, the fluid level may drop as measured within the reservoir. Don't assume there is an external fluid leak just because the fluid level in the reservoir is down to the Add mark. Restart the engine and see if the noise goes away after turning the steering wheel lock to lock a few times. This will correct most, if not all, the vehicles with a noise condition. If the customer was told their was a power steering fluid leak by an aftermarket service facility because the power steering reservoir needed fluid and they saw oil residue on the power steering gear, then carefully inspect the gear and surrounding area for oil residue. Below are some causes as to why oil residue may be present. Oil residue on the body of the steering gear usually on the pinion area (left side) of the gear or on the convoluted boots. This condition could be caused by a small amount of oil that can drip out when the shipping plugs are removed from the gear, just prior to the installation of the P/S pressure and return lines being connected at the assembly plants. Gears should not be replaced for this condition. Oil residue on or near the pinion adjuster nut plug. During the gear assembly process the supplier uses grease to lubricate the pinion adjuster plug threads. In cases where a lot of grease was used on the adjuster plug threads, some grease can ooze out around the threads and when mixed with moisture and road grime, it can appear as though the plug is leaking. In some cases the heat generated from the exhaust system will start to liquefy some of the grease and cause it to run. Gears should not be replaced for this condition. Oil residue inside the convoluted boots. When the steering gear is assembled into the housing, grease is applied to the gear teeth. In some cases, if there is a lot of grease used, it will squeeze out of the gear teeth, soften and run down and collect in the bottom of the convolutes. This may have the appearance of a thick oil, especially in hot climates. Some technicians have seen this liquefied grease and thought is was power steering fluid. Gears should not be replaced for this condition. If the customer indicates that they have seen what they think was a leak, resembling oil residue, on their garage floor or driveway, or the technician sees Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise > Page 1723 drops of oil leaking, carefully inspect the power steering hydraulic system. The inspection should be performed while the engine is running and the steering wheel is rotated from lock to lock. If a leak is observed, then repair the source of the leak. If the noise is not the result of low power steering fluid, provide a complete description of when the noise happens and what type of noise it is; i.e. squeal, pop, clunk, tick, continuous rubbing, etc. If it is a pop or clunk noise, make sure you inspect the convoluted boots to determine if the inner tie rod is rubbing the boots. Replace the boot or boots only for this condition. If the noise is a clunk or pop noise and it's not the inner tie rod rubbing the convoluted boots, make sure to inspect the intermediate shaft for the slip stick condition. This should be done prior to replacing any steering gears. If amber/yellow tinted glasses and the "pen light" style of black light are used, the lithium in the grease will show up in greenish/yellow similar to the greenish/yellow dye used by many dealerships to test for leaks. Always use the black light recommended by GM Tools and clear glasses to inspect for dye in fluid leaks. If the source of the leak cannot be found by visual inspection, add dye, P/N 88861206 (in Canada, use P/N 88861259), and inspect the system using Black Light (J 28428-E or J 42220). The number of vehicles that will require a complete inspection using dye will be minimal based on the inspection of numerous steering gears returned for testing where the complaint was fluid leak and no leaks could be reproduced. If a steering gear is replaced because a leak was discovered using the dye test method, make sure the repair order has a description of where the leak was discovered. If the steering gear is replaced for a noise concern, make sure a complete description of the diagnosis appears on the repair order as described in Step 5 above. Steering gears replaced under warranty will continue to be on parts return and regional feedbacks will be processed on any gears which the customer complaint cannot be verified. Over 90% of all steering gears inspected have little or no explanation of the condition, the technician's diagnosis or reason for replacing the gears and/or did not have any indication that dye was used to find a leak. Parts Information Warranty Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > NHTSA04V287000 > Jun > 04 > Recall 04V287000: Caliper Mounting Bolt Torque Front Steering Knuckle: All Technical Service Bulletins Recall 04V287000: Caliper Mounting Bolt Torque DEFECT: Certain passenger vehicles were produced with lower than specified torque on both front brake calipers to steering knuckle attachment bolts. With improper torque, the clamp load at the joint may not be adequate to prevent movement between the caliper bracket and knuckle. Depending on whether one or both bolts backs out or fractures, the result can be locking of the affected wheel during braking and an abrupt steering input in the direction of the locked wheel, reduced braking and noise from the affected wheel, or severing of a brake hose, increased brake pedal travel, and reduced steering control. Reduced braking or steering control could cause a crash. REMEDY: Dealers are to tighten both bolts to the specified torque. The manufacturer has reported that owner notification began on July 6, 2004. Owners may contact Chevrolet at 1-800-630-2438 or Pontiac at 1-800-620-7668. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering Fluid ........................................................................................................................... .................................................... 1.1 pints (1.0 liters) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 1736 Power Steering Fluid: Fluid Type Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 1741 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 1742 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Air Conditioning Refrigerant ................................................................................................................ ......................................................... 2.4 lb. (1.1 kg.) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1745 Refrigerant: Fluid Type Specifications Air Conditioning Refrigerant ....................................................................................................................... R134a P/N 12356150 U.S. (10953485 Canada) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1746 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector CAUTION: - Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: - R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. - To avoid system damage use only R-134a dedicated tools when servicing the A/C system. - Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. - R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. A/C Refrigerant System Oil Charge Replenishing If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES A/C COMPRESSOR REPLACEMENT ................................................................................................................................................. 75 ml (2.5 oz) NOTE: The 7CVC service compressor is shipped with 5.0 oz of PAG oil. If more than the specified amount of PAG oil was drained from a component, add the amount drained. IMPORTANT: Compressor failure can occur if the oil removed during refrigerant recovery is not replaced. CONDENSER REPLACEMENT ............................................................................................................................................................ 60 ml (2.0 oz) EVAPORATOR REPLACEMENT ......................................................................................................................................................... 90 ml (3.0 oz) RECEIVER DEHYDRATOR REPLACEMENT ................................................................................................................................... 30 ml (1.0 oz) NOTE: Add PAG oil equal to the amount of oil drained from the old receiver dehydrator, plus the specified amount. ANY LINE SET (HOSE/TUBE OR TUBE ASSEMBLY)....................................................................................................................... 30 ml (1.0 oz) TOTAL SYSTEM PAG OIL CAPACITY ......................................................................................................................................... 240.0 ml (8.0 oz) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1753 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL PAG Oil GM P/N 12378526 (Canadian P/N 88900060) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Bleeding the ABS System Perform a manual or pressure bleeding procedure. If the desired brake pedal height results are not achieved, perform the automated bleed procedure below. The procedure cycles the system valves and runs the pump in order to purge the air from the secondary circuits normally closed off during normal base brake operation and bleeding. The automated bleed procedure is recommended when air ingestion is suspected in the secondary circuits, or when the BPMV has been replaced. Automated Bleed Procedure Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove all four tire and wheel assemblies. 3. Inspect the brake system for leaks and visual damage. Refer to Brake Fluid Loss or Symptoms - Hydraulic Brakes. Repair or replace as needed. 4. Inspect the battery state of charge. 5. Install a scan tool. 6. Turn ON the ignition, with the engine OFF. 7. With the scan tool, establish communications with the EBCM. Select Special Functions. Select Automated Bleed from the Special Functions menu. 8. Bleed the base brake system. 9. Follow the scan tool directions until the desired brake pedal height is achieved. 10. If the bleed procedure is aborted, a malfunction exists. Perform the following steps before resuming the bleed procedure: ^ If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List and diagnose the appropriate DTC. ^ If the brake pedal feels spongy, perform the conventional brake bleed procedure again. 11. When the desired pedal height is achieved, press the brake pedal in order to inspect for firmness. 12. Remove the scan tool. 13. Install the tire and wheel assemblies. 14. Inspect the brake fluid level. 15. Road test the vehicle while inspecting that the pedal remains high and firm. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1759 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left front hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT - wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated. Refer to Symptoms - Hydraulic Brakes. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1760 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 35589-A Brake Pressure Bleeder Adapter Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add Delco Supreme II (R) (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, if cap removal is necessary. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder, (after all air has been purged from the front port of the master cylinder), loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II (R) (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J29532, or equivalent. Add Delco Supreme II (R) (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532, or equivalent, to the J 35589-A. 8. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 12. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II (R) (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 13. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 14. With the right rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the right rear hydraulic circuit), install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 12-13. 15. With the left front wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the left front hydraulic circuit), install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 12-13. 16. With the left rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the left rear hydraulic circuit), install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 12-13. 17. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 18. Close the J 29532, or equivalent, fluid tank valve, then disconnect the J 29532, or equivalent, from the J 35589-A. 19. Remove the J 35589-A from the brake master cylinder reservoir. 20. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II (R) (GM P/N 12377967) or equivalent DOT-3 brake fluid Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1761 from a clean, sealed brake fluid container. 21. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 22. If the brake pedal feels spongy perform the following steps: 22.1. Inspect the brake system for external leaks. 22.2. If equipped with Antilock Brakes, using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 23. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 24. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 1762 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Disabling And Enabling Zones Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1767 The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1768 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the radiator upper air baffle and deflector. 7. Remove the orange connector position assurance (CPA) (2) from the yellow sensor harness connector (3). 8. Disconnect the sensor harness connector from the sensor (1). Zone 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1769 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the side impact sensor (SIS)-LF from the center pillar. 7. Remove the connector position assurance (CPA) from the SIS-LF connector (2). 8. Disconnect the SIS-LF connector (2) from the SIS-LF (1). Zone 3 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1770 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the LH insulator panel. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Disconnect the steering wheel module coil connector. Zone 5 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1771 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the RH IP access hole cover. 7. Remove the connector position assurance (CPA) from the inflatable restraint IP module connector located to the right of the steering column. 8. Disconnect the IP module connector. Zone 7 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1772 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the fuse block access cover. 5. Remove the SIR Fuse. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the side impact module - LF connector (1) located under the driver seat. 7. Disconnect the side impact module - LF connector (1). Zone 9 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1773 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the I/P fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the LH insulator panel. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Disconnect the steering wheel module coil connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1774 9. Remove the RH I/P access hole cover. 10. Remove the CPA from the inflatable restraint I/P module connector, located at the RH side of the I/P. 11. Disconnect the I/P module connector. 12. Remove the CPA from the inflatable restraint side impact module - LF connector (1), located under the driver seat. 13. Disconnect the side impact module - LF connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1775 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition. 2. Connect the sensor harness connector (3) to the sensor (1). 3. Install the orange CPA (2) into the yellow sensor harness connector (3). 4. Install the radiator upper air baffle and deflector. 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash seven times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1776 1. Connect the SIS-LF connector (2) to the SIS-LF (1). 2. Install the CPA to the SIS-LF connector(2). 3. Install the side impact sensor (SIS)-LF into the center pillar. 4. Install the SIR Fuse. 5. Install the fuse block access cover. 6. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. 2. Connect the steering wheel module coil connector. 3. Install the CPA from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 4. Install the LH insulator panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1777 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash seven times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the IP module connector. 3. Install the CPA into the IP module connector located to the right of the steering column. 4. Install the LH insulator panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1778 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Connect the inflatable restraint side impact module - LF connector (1) located under the driver seat. 2. Install the CPA to the side impact module - LF connector (1). 3. Remove the SIR Fuse. 4. Install the fuse block access cover. 5. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 5.1. The AIR BAG indicator will flash seven times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1779 1. Remove the key from the ignition. Connect the inflatable restraint side impact module - LF connector (1), located under the driver seat. 2. Install the CPA to the side impact module - LF connector. 3. Connect the inflatable restraint I/P module connector, located at the RH side of the I/P. 4. Install the CPA to the I/P module connector. 5. Install the RH I/P access hole cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 1780 6. Connect the steering wheel module coil connector. 7. Install the CPA from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Install the LH insulator panel. 9. Install the SIR Fuse. 10. Install the LH I/P access hole cover. 11. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 11.1. The AIR BAG indicator will flash seven times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block Fuse Block: Locations Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1790 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1791 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1792 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1793 Fuse Block: Locations Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1794 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1795 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1796 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1797 Fuse Block: Locations Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1798 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1799 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1800 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1801 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1802 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1803 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1804 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1805 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1806 Fuse Block: Locations Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1807 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1808 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1809 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1810 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1811 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1812 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1813 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 1814 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - SEO Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1817 Fuse Block - SEO Part 2 Junction Block - Left I/P - C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1818 Junction Block-Left I/P - C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1819 Junction Block-Left I/P - C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1820 Junction Block-Left I/P - C1 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1821 Junction Block-Left I/P - C1 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1822 Junction Block-Left I/P - C1 Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1823 Junction Block-Left I/P - C1 Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1824 Junction Block-Left I/P - C1 Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1825 Junction Block-Left I/P - C1 Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1826 Junction Block-Left I/P - C1 Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1827 Junction Block-Left I/P - C1 Part 10 Junction Block - Left I/P - C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1828 Junction Block-Left I/P - C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1829 Junction Block-Left I/P - C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1830 Junction Block-Left I/P - C2 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1831 Junction Block-Left I/P - C2 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1832 Junction Block-Left I/P - C2 Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1833 Junction Block-Left I/P - C2 Part 6 Junction Block - Right I/P - C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1834 Junction Block-Right I/P - C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1835 Junction Block-Right I/P - C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1836 Junction Block-Right I/P - C1 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1837 Junction Block-Right I/P - C1 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1838 Junction Block-Right I/P - C1 Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1839 Junction Block-Right I/P - C1 Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1840 Junction Block-Right I/P - C1 Part 7 Junction Block - Right I/P - C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1841 Junction Block-Right I/P - C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1842 Junction Block-Right I/P - C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1843 Junction Block-Right I/P - C2 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1844 Junction Block-Right I/P - C2 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1845 Junction Block-Right I/P - C2 Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1846 Junction Block-Right I/P - C2 Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1847 Junction Block-Right I/P - C2 Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Connector Views > Page 1848 Junction Block-Right I/P - C2 Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block Fuse Block: Application and ID Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1851 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1852 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1853 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1854 Fuse Block: Application and ID Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1855 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1856 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1857 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1858 Fuse Block: Application and ID Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1859 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1860 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1861 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1862 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1863 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1864 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1865 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1866 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1867 Fuse Block: Application and ID Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1868 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1869 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1870 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1871 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1872 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1873 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1874 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 1875 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the positive battery cables from the underhood fuse block terminals. 3. Remove the tape from the wiring harness at the base of the underhood fuse block base. 4. Release the underhood fuse block(s) clip retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1878 5. Remove the fuse block(s) and wiring harness lifting up from the base and reposition from the base. 6. Remove the nuts from the underhood fuse block base. 7. Remove the underhood fuse block base from the shock tower. 8. Remove the underhood fuse block lower front terminal positive assurance retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1879 9. Remove the plastic shields from the battery cable and buss bar terminals, using a small flat-bladed tool to release the clip retainer. 10. Remove the bolts from the buss bar jumper bar. 11. Remove the buss bar jumper bar from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1880 12. Remove the fuses from the fuse block(s) to access the buss bar terminal release tabs. 13. Remove the buss bar(s) from the fuse block(s) using a terminal releasing tool, and pulling down and out on the buss bar. 14. Remove the buss bar(s) from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1881 15. Release the clip retainers from the underhood fuse block(s) battery cable and buss bar terminals using a small flat-bladed tool. 16. Remove the underhood fuse block(s) battery cable and buss bar terminals from the fuse block by pulling down. 17. Remove the fuse block and lamp wiring harness from the vehicle, if required. INSTALLATION PROCEDURE 1. Install the underhood fuse block(s) battery cable and buss bar terminals to the fuse block(s) by sliding up into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1882 2. Install the buss bar(s) to the fuse block(s) pressing into place until fully seated. 3. Position the underhood fuse block terminal positive assurance retainers to the fuse block(s). 4. Install the underhood fuse block(s) terminal positive assurance retainers pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1883 5. Install the fuses to the fuse block(s) that were removed to access the buss bar terminal release tabs. 6. Install the buss bar jumper bar to the fuse block(s). NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the bolts to the buss bar jumper bar. Tighten Tighten the jumper bar bolts to 9 N.m (80 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1884 8. Install the plastic shields to the battery cable and buss bar terminals pressing into place until fully seated. 9. Position the underhood fuse block(s) to the underhood fuse block base retaining locks. 10. Install the underhood fuse block(s) into the underhood fuse block base retaining locks pressing in until fully seated. 11. Install new tape to the wiring harness at the base of the underhood fuse block base. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1885 12. Position the underhood fuse block base to the shock tower. 13. Install the nuts to the underhood fuse block base. Tighten Tighten the fuse block base nuts to 9 N.m (80 lb in). 14. Install the positive battery cables to the underhood fuse block. Tighten Tighten the positive battery cables nuts to 15 N.m (11 lb ft). 15. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1886 Fuse Block: Service and Repair Instrument Panel Electrical Center / Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left I/P fuse block access hole cover. 3. Disconnect the outboard wiring harness connector C2 from the junction block. 4. Remove the connector position assurance (CPA) from the yellow inflatable restraint connector. Disconnect and reposition the yellow inflatable restraint connector for access to the bolts. 5. Remove the steering column filler. 6. Remove the I/P driver knee bolster. 7. Disconnect the inner wiring harness connector from the junction block. 8. Remove the junction block bolts. 9. Remove the junction block tab from the slot in the cross vehicle beam. Pull the junction block away from the I/P. 10. Remove the junction block. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1887 1. Install the junction block tab to the slot in the cross vehicle beam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the junction block bolts. Tighten Tighten the junction block bolts to 10 N.m (89 lb in). 3. Connect the inner wiring harness connector to the junction block. Tighten Tighten the inner wiring harness connector bolt to 7 N.m (62 lb in). 4. Install the I/P driver knee bolster. 5. Install the steering column filler. 6. Connect the yellow inflatable restraint connector. Install the CPA. Attach the connector to the junction block. 7. Connect the outboard wiring harness connector C2 to the junction block. Tighten Tighten the body wiring harness connector bolt to 7 N.m (62 lb in). 8. Install the left I/P fuse block access hole cover. 9. Connect the negative battery cable. Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1888 REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the RH instrument panel (IP) fuse block access opening cover. 3. Disconnect the body wiring harness from the junction block. 4. Open the IP compartment. Access the junction block bolt through the open IP compartment. Remove the junction block bolt. 5. Disengage the junction block tabs from the passenger knee bolster. Pull the junction block away from the IP. 6. Disconnect the wiring harnesses from the junction block. 7. Remove the junction block. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1889 1. Connect the body wiring harnesses to the junction block. Tighten Tighten the body wiring harness connector bolts to 7 N.m (62 lb in). 2. Install the junction block tabs to the passenger knee bolster. 3. Install the junction block bolt. Tighten Tighten the junction block bolt to 10 N.m (89 lb in). 4. Close the IP compartment. 5. Connect the body wiring harness to the junction block. 6. Install the RH IP fuse block access opening cover. 7. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1890 Fuse Block: Service and Repair Junction Block Replacement - Accessory Wiring JUNCTION BLOCK REPLACEMENT - ACCESSORY WIRING REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left instrument panel (I/P) insulator. 3. Remove the screws from the accessory wiring junction block. 4. Adjust the junction block for access. 5. Remove the circuit breakers (4) and the relays from the junction block as required. 6. If necessary remove the junction block from the bracket assembly. INSTALLATION PROCEDURE 1. If necessary install the junction block to the bracket assembly. 2. Install the circuit breakers (4) and the relays to the junction block as required. 3. Position the junction block to the I/P carrier. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the junction block screws. Tighten Tighten the screws to 10 N.m (89 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1891 5. Install the left I/P insulator. 6. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block Relay Box: Locations Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1896 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1897 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1898 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1899 Relay Box: Locations Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1900 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1901 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1902 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1903 Relay Box: Locations Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1904 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1905 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1906 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1907 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1908 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1909 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1910 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1911 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1912 Relay Box: Locations Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1913 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1914 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1915 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1916 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1917 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1918 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1919 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 1920 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block Relay Box: Application and ID Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1923 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1924 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1925 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1926 Relay Box: Application and ID Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1927 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1928 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1929 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1930 Relay Box: Application and ID Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1931 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1932 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1933 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1934 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1935 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1936 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1937 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1938 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1939 Relay Box: Application and ID Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1940 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1941 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1942 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1943 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1944 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1945 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1946 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 1947 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the positive battery cables from the underhood fuse block terminals. 3. Remove the tape from the wiring harness at the base of the underhood fuse block base. 4. Release the underhood fuse block(s) clip retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1950 5. Remove the fuse block(s) and wiring harness lifting up from the base and reposition from the base. 6. Remove the nuts from the underhood fuse block base. 7. Remove the underhood fuse block base from the shock tower. 8. Remove the underhood fuse block lower front terminal positive assurance retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1951 9. Remove the plastic shields from the battery cable and buss bar terminals, using a small flat-bladed tool to release the clip retainer. 10. Remove the bolts from the buss bar jumper bar. 11. Remove the buss bar jumper bar from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1952 12. Remove the fuses from the fuse block(s) to access the buss bar terminal release tabs. 13. Remove the buss bar(s) from the fuse block(s) using a terminal releasing tool, and pulling down and out on the buss bar. 14. Remove the buss bar(s) from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1953 15. Release the clip retainers from the underhood fuse block(s) battery cable and buss bar terminals using a small flat-bladed tool. 16. Remove the underhood fuse block(s) battery cable and buss bar terminals from the fuse block by pulling down. 17. Remove the fuse block and lamp wiring harness from the vehicle, if required. INSTALLATION PROCEDURE 1. Install the underhood fuse block(s) battery cable and buss bar terminals to the fuse block(s) by sliding up into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1954 2. Install the buss bar(s) to the fuse block(s) pressing into place until fully seated. 3. Position the underhood fuse block terminal positive assurance retainers to the fuse block(s). 4. Install the underhood fuse block(s) terminal positive assurance retainers pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1955 5. Install the fuses to the fuse block(s) that were removed to access the buss bar terminal release tabs. 6. Install the buss bar jumper bar to the fuse block(s). NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the bolts to the buss bar jumper bar. Tighten Tighten the jumper bar bolts to 9 N.m (80 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1956 8. Install the plastic shields to the battery cable and buss bar terminals pressing into place until fully seated. 9. Position the underhood fuse block(s) to the underhood fuse block base retaining locks. 10. Install the underhood fuse block(s) into the underhood fuse block base retaining locks pressing in until fully seated. 11. Install new tape to the wiring harness at the base of the underhood fuse block base. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1957 12. Position the underhood fuse block base to the shock tower. 13. Install the nuts to the underhood fuse block base. Tighten Tighten the fuse block base nuts to 9 N.m (80 lb in). 14. Install the positive battery cables to the underhood fuse block. Tighten Tighten the positive battery cables nuts to 15 N.m (11 lb ft). 15. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1958 Relay Box: Service and Repair Instrument Panel Electrical Center / Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left I/P fuse block access hole cover. 3. Disconnect the outboard wiring harness connector C2 from the junction block. 4. Remove the connector position assurance (CPA) from the yellow inflatable restraint connector. Disconnect and reposition the yellow inflatable restraint connector for access to the bolts. 5. Remove the steering column filler. 6. Remove the I/P driver knee bolster. 7. Disconnect the inner wiring harness connector from the junction block. 8. Remove the junction block bolts. 9. Remove the junction block tab from the slot in the cross vehicle beam. Pull the junction block away from the I/P. 10. Remove the junction block. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1959 1. Install the junction block tab to the slot in the cross vehicle beam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the junction block bolts. Tighten Tighten the junction block bolts to 10 N.m (89 lb in). 3. Connect the inner wiring harness connector to the junction block. Tighten Tighten the inner wiring harness connector bolt to 7 N.m (62 lb in). 4. Install the I/P driver knee bolster. 5. Install the steering column filler. 6. Connect the yellow inflatable restraint connector. Install the CPA. Attach the connector to the junction block. 7. Connect the outboard wiring harness connector C2 to the junction block. Tighten Tighten the body wiring harness connector bolt to 7 N.m (62 lb in). 8. Install the left I/P fuse block access hole cover. 9. Connect the negative battery cable. Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1960 REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the RH instrument panel (IP) fuse block access opening cover. 3. Disconnect the body wiring harness from the junction block. 4. Open the IP compartment. Access the junction block bolt through the open IP compartment. Remove the junction block bolt. 5. Disengage the junction block tabs from the passenger knee bolster. Pull the junction block away from the IP. 6. Disconnect the wiring harnesses from the junction block. 7. Remove the junction block. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1961 1. Connect the body wiring harnesses to the junction block. Tighten Tighten the body wiring harness connector bolts to 7 N.m (62 lb in). 2. Install the junction block tabs to the passenger knee bolster. 3. Install the junction block bolt. Tighten Tighten the junction block bolt to 10 N.m (89 lb in). 4. Close the IP compartment. 5. Connect the body wiring harness to the junction block. 6. Install the RH IP fuse block access opening cover. 7. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1962 Relay Box: Service and Repair Junction Block Replacement - Accessory Wiring JUNCTION BLOCK REPLACEMENT - ACCESSORY WIRING REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left instrument panel (I/P) insulator. 3. Remove the screws from the accessory wiring junction block. 4. Adjust the junction block for access. 5. Remove the circuit breakers (4) and the relays from the junction block as required. 6. If necessary remove the junction block from the bracket assembly. INSTALLATION PROCEDURE 1. If necessary install the junction block to the bracket assembly. 2. Install the circuit breakers (4) and the relays to the junction block as required. 3. Position the junction block to the I/P carrier. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the junction block screws. Tighten Tighten the screws to 10 N.m (89 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 1963 5. Install the left I/P insulator. 6. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 1971 Malfunction Indicator Lamp: Service and Repair SERVICE VEHICLE SOON INDICATOR The "SERVICE VEHICLE SOON" light will come on if there are certain non-emission related vehicle problems. These problems may not be obvious and may affect vehicle performance or durability. The light will come on briefly when the ignition is turned on to show that it is working properly. This light does NOT come on at certain mileage intervals. There is probably a PCM or a BCM Code set that will aid you in diagnosis. RESET PROCEDURE The only way to get the light to go off is to clear the PCM or BCM code(s). This light can NOT be reset or shut off any other way. PCM/BCM codes should be read & repaired before clearing them. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Instruments - Oil Life Monitoring System Oil Change Reminder Lamp: Technical Service Bulletins Instruments - Oil Life Monitoring System Bulletin No.: 04-06-04-045 Date: June 22, 2004 INFORMATION Subject: Oil Life Monitoring System - PCM Reset Models: 2004 All GM Passenger Cars and Trucks Important: The Oil Life Monitoring System can be found on many General Motor's vehicles prior to 2004. Refer to SI and/or the Owner's Manual for detailed information. The purpose of this bulletin is to help technicians identify which vehicles are equipped with the oil life monitoring system. Although many General Motors vehicles prior to 2004 have been equipped with the oil life monitoring system, the 2004 model year vehicles were used as a starting point to validate the system/scan tool functionality. Customers have come to depend on the Oil Life Monitoring System found on most General Motor's vehicles to inform them when it's time for an oil change. If for any reason the PCM is replaced, it is important to access the "Percent of Oil Life Remaining" from the vehicle's current PCM PRIOR to removing the PCM. This value must be programmed into the new PCM (after it is installed in the vehicle) by using the scan tool. Note: Failure to reprogram the value to the new PCM will result in missed maintenance, which may cause damage to the engine. Important: If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to changed at 5,000 km (3,000 mi) from the last engine oil change. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Page 1976 Oil Change Reminder Lamp: Description and Operation WHEN TO CHANGE ENGINE OIL Your vehicle has a computer system that lets you know when to change the engine oil and filter. This is based on engine revolutions and engine temperature and on a maximum mileage of 10,000 miles (16 000 km). Under severe conditions the indicator may come on before 10,000 miles (16 000 km). Never drive your vehicle more then 10,000 miles (16 000 km) or 12 months without an oil and filter change. Based on driving conditions, the mileage at which an oil change will be indicated can vary considerably. For the oil life system to work properly, you must reset the system every time the oil is changed. When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A "CHANGE ENGINE OIL" message or a "CHANGE OIL" indicator will come on. Change your oil as soon as possible within the next two times you stop for fuel. It is possible that, if you are driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, your engine oil and filter must be changed at least once a year and at this time the system must be reset. It is also important to check your oil regularly and keep it at the proper level. The engine oil life monitor will not detect dust in the oil. If the vehicle is driven in a dusty area, be sure to change the oil every 5,000 km (3,000 miles) or sooner if the "CHANGE ENGINE OIL" light is displayed. If the system is ever reset accidentally, you must change your oil at 10,000 miles (16 000 km) since your last oil change. Remember to reset the oil life system whenever the oil is changed. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Page 1977 Oil Change Reminder Lamp: Service and Repair GM OIL LIFE SYSTEM - RESETTING USING THE RADIO 1. Turn the ignition to "ACC" OR "ON", with the radio off. 2. Press and hold the "TUNE DISP" button on the radio for at least five seconds until "SETTINGS" is displayed. 3. Press the "SEEK PTYPE" or the "SEEK PSCAN" up or down arrow to scroll through the main menu. 4. Scroll until "OIL LIFE" appears on the display. 5. Press the "1 PREV" or "2 NEXT" button to enter the submenu. "RESET" will be displayed. 6. Press the "TUNE DISP" button to reset. A chime will be heard to verify the new setting and "DONE" will be displayed for one second. 7. Once the message has been reset, scroll until "EXIT" appears on the display. 8. Press the "TUNE DISP" button to exit programming. A chime will be heard to verify the exit. USING THE ACCELERATOR PEDAL 1. Turn the ignition to "ON", with the engine off. 2. Fully press and release the accelerator pedal three times within five seconds. If the "CHANGE ENGINE OIL" message flashes, the system is reset. However, if it stays on , it did not reset. Repeat the procedure. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 1993 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2007 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2012 Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires INFORMATION Bulletin No.: 05-03-10-020C Date: April 27, 2010 Subject: Use of Nitrogen Gas in Tires Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-03-10-020B (Section 03 - Suspension). GM's Position on the Use of Nitrogen Gas in Tires General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical benefits, practical limitations, and the robust design of GM original equipment TPC tires, the realized benefits to our customer of inflating their tires with purified nitrogen are expected to be minimal. The Promise of Nitrogen: Under Controlled Conditions Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. The following benefits under controlled conditions are attributed to nitrogen gas and its unique properties: - A reduction in the expected loss of Tire Pressure over time. - A reduction in the variance of Tire Pressures with temperature changes due to reduction of water vapor concentration. - A reduction of long term rubber degradation due to a decrease in oxygen concentrations. Important These are obtainable performance improvements when relatively pure nitrogen gas is used to inflate tires under controlled conditions. The Promise of Nitrogen: Real World Use Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration) has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing. The actual obtainable benefits of nitrogen vary, based on the physical construction and the materials used in the manufacturing of the tire being inflated. Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are required to begin the normal oxidation process. Even slight contamination of the tire inflation gas with compressed atmospheric air during normal inflation pressure maintenance, may negate the benefits of using nitrogen. GM Tire Quality, Technology and Focus of Importance Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria) specification system, which includes specific requirements that ensure robust tire performance under normal usage. General Motors works with tire suppliers to design and manufacture original equipment tires for GM vehicles. The GM TPC addresses required performance with respect to both inflation pressure retention, and endurance properties for original equipment tires. The inflation pressure retention requirements address availability of oxygen and oxidation concerns, while endurance requirements ensure the mechanical structure of the tire has sufficient strength. This combination has provided our customers with tires that maintain their structural integrity throughout their useful treadlife under normal operating conditions. Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear, and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation pressure maintenance is necessary for the tire to support the load imposed by the vehicle without excessive structural Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2013 degradation. Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2014 Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures INFORMATION Bulletin No.: 04-03-10-001F Date: April 27, 2010 Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-001E (Section 03 - Suspension). This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in the tread area only. The tire manufacturer must be contacted for its individual repair policy and whether or not the speed rating is retained after repair. Caution - Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. - Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. - NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. - NEVER stand, lean or reach over the assembly during inflation. Repairable area on a radial tire. Important - NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth). - NEVER repair tires with a tread puncture larger than 6.35 mm (1/4"). - NEVER substitute an inner tube for a permissible or non-permissible repair. - NEVER perform an outside-in tire repair (plug only, on the wheel). - Every tire must be removed from the wheel for proper inspection and repair. - Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. - Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2015 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2016 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Important Do not install the repair unit in this step. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2017 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2018 1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads excessively). Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. 2. Consult your repair material supplier for the proper stitching tool. Safety Cage Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2019 Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - OFF Vehicle. For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA) Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2020 Tires: Technical Service Bulletins Tires - Correct Inflation Pressure Information INFORMATION Bulletin No.: 00-00-90-002J Date: January 28, 2009 Subject: Information on Proper Tire Pressure Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3, H3T 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and clarify additional information. Please discard Corporate Bulletin Number 00-00-90-002I (Section 00 - General Information). Important: ^ Adjustment of tire pressure for a customer with a Low Tire Pressure Monitor (TPM) light on and no codes in the TPM system is NOT a warrantable repair. Claims to simply adjust the tire pressure will be rejected. ^ ALL tires (including the spare tire) MUST be set to the recommended inflation pressure stated on the vehicle's tire placard (on driver's door) during the PRE-DELIVERY INSPECTION (PDI). Recommended inflation pressure is not the pressure printed on tire sidewall. ^ Tires may be over-inflated from the assembly plant due to the mounting process. ^ Generally a 5.6°C (10°F) temperature change will result in (is equivalent to) a 6.9 kPa (1 psi) tire pressure change. ^ 2008-2009 HUMMER H2 Only - The H2 comes standard with Light Truck "D" Load Range tires with a recommended cold inflation pressure of 289 kPa (42 psi). These tires will alert the driver to a low pressure situation at roughly 262 kPa (38 psi) due to a requirement in FMVSS 138 which specifies a Minimum Activation Pressure for each tire type. This creates a relatively narrow window of "usable" pressure values and the warning will be more sensitive to outside temperature changes during the colder months. As with other cold temperature/tire pressure issues, there is nothing wrong with the system itself. If a vehicle is brought in with this concern, check for tire damage and set all tires to the Recommended Cold Inflation Pressure shown on the vehicle placard. Accurate tire pressures ensure the safe handling and appropriate ride characteristics of GM cars and trucks. It is critical that the tire pressure be adjusted to the specifications on the vehicle¡C■s tire placard during PDI. Ride, handling and road noise concerns may be caused by improperly adjusted tire pressure. The first step in the diagnosis of these concerns is to verify that the tires are inflated to the correct pressures. The recommended tire inflation pressure is listed on the vehicle¡C■s tire placard. The tire placard is located on the driver¡C■s side front or rear door edge, center pillar, or the rear compartment lid. Tip ^ Generally a 5.6°C (10°F) temperature increase will result in (is equivalent to) a 6.9 kPa (1 psi) tire pressure increase. ^ The definition of a "cold" tire is one that has been sitting for at least 3 hours, or driven no more than 1.6 km (1 mi). ^ On extremely cold days, if the vehicle has been indoors, it may be necessary to compensate for the low external temperature by adding additional air to the tire during PDI. ^ During cold weather, the Tire Pressure Monitor (TPM) indicator light (a yellow horseshoe with an exclamation point) may illuminate. If this indicator turns off after the tires warm up (reach operating temperature), the tire pressure should be reset to placard pressure at the cold temperature. ^ The TPM system will work correctly with nitrogen in tires. ^ The TPM system is compatible with the GM Vehicle Care Tire Sealant but may not be with other commercially available sealants. Important: ^ Do not use the tire pressure indicated on the tire itself as a guide. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 2021 ^ Always inspect and adjust the pressure when the tires are cold. ^ Vehicles that have different pressures for the front and the rear need to be adjusted after tire rotation. Improper tire inflation may result in any or all of the following conditions: ^ Premature tire wear ^ Harsh ride ^ Excessive road noise ^ Poor handling ^ Reduced fuel economy ^ Low Tire Pressure Monitor (TPM) Light ON ^ Low Tire Pressure Message on the Drivers Information Center (DIC) Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 2022 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Removal and Installation Tires: Service and Repair Tire and Wheel Removal and Installation Tire and Wheel Removal and Installation ^ Tools Required J 39544-KIT Complete Torque Socket Set Removal Procedure Caution: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident Notice: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. Notice: Removing wheels can be difficult because of foreign material or a tight fit between the wheel center hole and the hub or rotor. Excessive force, such as hammering on the wheel or tire, can cause damage. Slightly tapping the tire side wall with a rubber mallet is acceptable. 1. Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut 2 turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel nuts from the tire and wheel assembly. 3. Mark the location of the tire and wheel assembly to the hub assembly. 4. Remove the tire and wheel assembly from the vehicle. 5. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. Installation Procedure Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. Notice: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Removal and Installation > Page 2025 1. Install the tire and wheel assembly. Align the locating mark of the tire and wheel to the hub. Notice: Refer to Fastener Notice in Service Precautions. Important: Tighten the nuts evenly and alternately in order to avoid excessive runout. 2. Install the wheel nuts. ^ Tighten the nuts in a cries-cross pattern to 140 Nm (100 ft. lbs.). 3. Remove the safety stands and lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Removal and Installation > Page 2026 Tires: Service and Repair Tire Mounting and Dismounting Tire Mounting and Dismounting Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. Notice: Damage to either the tire bead or the wheel mounting holes can result from the use of improper wheel attachment or tire mounting procedures. It takes up to 70 seconds for all of the air to completely exhaust from a large tire. Failure to follow the proper procedures could cause the tire changer to put enough force on the tire to bend the wheel at the mounting surface. Such damage may result in vibration and/or shimmy, and under severe usage lead to wheel cracking. 1. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 2. Use the tire changer in order to remove the tire from the wheel. 3. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Notice: When mounting the tires, use an approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A silicon base compound can cause the tire to slip on the rim. A corrosive type compound can cause tire or rim deterioration. 4. Apply GM P/N 12345884 (Canadian P/N 5728223) or equivalent to the tire bead and the wheel rim. 5. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal injury. 6. Inflate the tire to the proper air pressure. 7. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Removal and Installation > Page 2027 Tires: Service and Repair Tire Repair Tire Repair Many different materials and techniques are available on the market in order to repair tires. Not all of the materials and techniques work on some types of tires. Tire manufacturers have published detailed instructions on how and when to repair tires. Obtain the instructions from the manufacturer. If the vehicle is equipped with a compact spare tire, do not repair the compact spare. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Removal and Installation > Page 2028 Tires: Service and Repair Tire Rotation Tire Rotation Rotate the tires and wheels at frequent intervals to equalize wear. In addition to scheduled rotation, rotate the tire and wheel whenever uneven tire wear is noticed. Radial tires tend to wear faster in the shoulder area, particularly in front positions. Radial tires in non-drive locations may develop an irregular wear pattern that may increase tire noise. This makes regular rotation especially necessary. Always use a 4-wheel rotation. After rotation, check the wheel nuts for specified torque. Then, set the tire pressure. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Removal and Installation > Page 2029 Tires: Service and Repair Tire and Wheel Rotation and Inspection TIRE AND WHEEL INSPECTION AND ROTATION Tires should be rotated every 8 000-13 000 km (5,000-8,000 mi). Any time you notice unusual wear, rotate the tires as soon as possible and test the wheel alignment. Also inspect for damaged tires or wheels. The purpose of regular rotation is to achieve more uniform wear for all tires on the vehicle. The first rotation is the most important. Refer to Scheduled Maintenance for scheduled rotation intervals. When rotating your tires, always use the correct rotation pattern shown here. Do not include the compact spare tire in your tire rotation. After the tires have been rotated, adjust the front and rear inflation pressures Refer to Tire Placard. Reset the Tire Inflation Monitor System. Ensure that all wheel nuts are properly tightened. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2038 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2039 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2040 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 2045 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2050 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2051 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2052 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2058 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2059 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2060 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 2065 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2070 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2071 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2076 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2077 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 2078 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 2083 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2088 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2089 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 2090 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2100 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2101 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 2102 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires - Refinishing Aluminum Wheels > Page 2107 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2112 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 2113 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 2118 Wheels: Description and Operation Replacement Wheels Description Replace the wheel if any of the following conditions exist: ^ The wheel exhibits excessive runout. ^ The wheel is bent. ^ The wheel is cracked. ^ The wheel is severely rusted. ^ The wheel is severely corroded. Important: Air leaks caused by porosity on aluminum wheels are repairable. ^ The wheel leaks air. Caution: If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components ^ Adverse vehicle steering stability caused by the modified scrub radius ^ Damage to the vehicle caused by the modified ground clearance ^ Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: ^ The wheel has elongated bolt holes. ^ The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. Steel Wheel Repair Description Notice: Do not heat wheels in an attempt to soften them for straightening or repair damage from striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and uncontrolled heating from welding affects the properties of the material. Notice: The use of tubes in tubeless tires is not a recommended repair due to the fact that speed ratings are greatly reduced. You can repair porosity in aluminum wheels. If leaks are found in a steel wheel, replace the wheel with a wheel of original equipment quality. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. Important: Do not damage the exterior surface of the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 8. Use general purpose cleaner such as EMS, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 in.) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 2121 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Important: ^ If the wheels are chrome-plated, do not re-plate or refinish the wheels. ^ If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. 2. Inspect the wheels for the following conditions: ^ Corrosion ^ Scrapes ^ Gouges 3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. Refinishing Procedure Caution: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the tire and wheel assembly from the vehicle. 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: ^ Lubricants ^ Wax ^ Dirt Important: ^ Do not re-machine the wheel. ^ Do not use chemicals in order to strip the paint from the wheel. 5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. Important: The wheel mounting surface and the wheel nut contact surface must remain free of paint. 7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint manufacturer's instructions for painting the wheel. 9. Unmask the wheel. 10. Install a new valve stem. Important: Use new coated balance weights in order to balance the wheel. 11. Install the tire to the wheel. 12. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: ^ Corrosion ^ Overspray ^ Dirt 13. Install the tire and wheel assembly to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 2122 Wheels: Service and Repair Tire and Wheel Removal and Installation Tire and Wheel Removal and Installation ^ Tools Required J 39544-KIT Complete Torque Socket Set Removal Procedure Caution: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident Notice: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. Notice: Removing wheels can be difficult because of foreign material or a tight fit between the wheel center hole and the hub or rotor. Excessive force, such as hammering on the wheel or tire, can cause damage. Slightly tapping the tire side wall with a rubber mallet is acceptable. 1. Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut 2 turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel nuts from the tire and wheel assembly. 3. Mark the location of the tire and wheel assembly to the hub assembly. 4. Remove the tire and wheel assembly from the vehicle. 5. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. Installation Procedure Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. Notice: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 2123 1. Install the tire and wheel assembly. Align the locating mark of the tire and wheel to the hub. Notice: Refer to Fastener Notice in Service Precautions. Important: Tighten the nuts evenly and alternately in order to avoid excessive runout. 2. Install the wheel nuts. ^ Tighten the nuts in a cries-cross pattern to 140 Nm (100 ft. lbs.). 3. Remove the safety stands and lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Front Wheel Bearing/Hub Bolts ............................................................................................................................................................. 130 Nm (96 ft. lbs.) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 2128 Wheel Bearing: Fluid Type Specifications FRONT WHEEL BEARINGS Wheel bearing lubricant meeting requirements of NLGI # 2, Category GC or GC-LB (GM Part No. U.S. 1051344, in Canada 993037). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 2129 Wheel Bearings Diagnosis Step 1-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Bearing/Hub Replacement - Front ^ Tools Required J 42129 Wheel Hub Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Disconnect the wheel speed sensor electrical connector (2), if equipped. 4. Remove the wheel speed sensor electrical connector from the bracket, if equipped. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2132 5. Remove the front wheel drive shaft nut (2). Insert a drift or flat bladed tool (1) into the caliper and rotor to prevent from turning. 6. Remove the brake rotor. 7. Use 3 wheel nuts in order to attach the J 42129 to the wheel bearing/hub. 8. Use the J 42129 in order to push the wheel drive shaft out of the wheel bearing/hub. 9. Remove and DISCARD the wheel bearing/hub bolts. Remove the J 42129 from the hub. Important: Ensure that the wheel drive shaft outer seal/boot is not damaged. 10. Remove the wheel bearing/hub and splash shield-noting the position of the shield for reinstallation. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2133 1. Install the wheel bearing/hub with the splash shield as noted during removal. Caution: These fasteners MUST be replaced with new fasteners anytime they become loose or are removed. Failure to replace these fasteners after they become loose or are removed may cause loss of vehicle control and personal injury. Notice: Refer to Fastener Notice in Service Precautions. 2. Install NEW wheel bearing/hub bolts. ^ Tighten the NEW wheel bearing/hub bolts to 130 Nm (96 ft. lbs.). 3. Install the brake rotor and caliper. 4. Install the front wheel drive shaft nut. Insert a drift on a flat bladed tool into caliper and rotor to prevent the rotor from turning. ^ Tighten the front wheel drive shaft nut to 160 Nm (118 ft. lbs.). Important: Ensure that the connector clip engages the bracket properly. 5. Install the wheel speed sensor electrical connector to the bracket, if equipped. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2134 6. Connect the wheel speed sensor electrical connector (2), if equipped. 7. Install the tire and wheel. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2135 Wheel Bearing: Service and Repair Rear Wheel Bearing/Hub Replacement - Rear Removal Procedure Important: The wheel bearing in the rear wheel hub is integrated into one unit. The hub is non-serviceable. If the hub and/or bearing is damaged, replace the complete hub and bearing assembly. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tires and wheels. 3. Remove the brake rotor. 4. Remove the ABS electrical connector from the wheel speed sensor (1), if equipped. 5. Remove the park brake cable from the park brake actuator. 6. Remove the mounting bolts from the rear bearing/hub. 7. Remove the wheel bearing/hub and park brake assembly from the knuckle. 8. Remove the park brake actuator from the rear wheel bearing/hub. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 2136 1. Install the park brake actuator to the rear wheel bearing/hub. 2. install the wheel bearing/hub and park brake assembly to the knuckle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the wheel bearing/hub-to-knuckle bolts. ^ Tighten the bolts to 75 Nm (55 ft. lbs.). 4. Install the park brake cable to the park brake actuator. 5. Install the ABS electrical connector to the wheel speed sensor (1), if equipped. 6. Install the brake rotor. 7. Install the tires and wheels. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Drive Shaft Nut ........................................................................................................................... ................................................... 160 N.m (118 lb ft) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 2149 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 2155 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 2156 Wheel Fastener: Specifications Wheel Nuts .......................................................................................................................................... ................................................. 140 Nm (100 ft. lbs.) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 2157 Wheel Nut Torque Sequence Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 2158 Wheel Fastener: Description and Operation Metric Wheel Nuts and Bolts Description Metric wheel/nuts and bolts are identified in the following way: ^ The wheel/nut has the word Metric stamped on the face. ^ The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. ^ M = Metric ^ 12 = Diameter in millimeters ^ 1.5 = Millimeters gap per thread Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement ^ Tools Required J 6627-A Tie Rod Puller Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper and bracket. Hang the caliper and the bracket from the vehicle. DO NOT allow the caliper and the bracket to hang by the brake hose. 4. Remove the brake rotor. 5. Use the J 6627-A in order to extract the stud (1) from the hub (2). Installation Procedure 1. Install a replacement stud in the wheel hub. 2. Add enough washers (3) in order to draw the stud into the hub (2). 3. Install the wheel nut (1) with the flat side against the washers (3). Important: Fully seat the wheel stud against the hub flange (2). 4. Tighten the wheel nut (1) until the wheel stud is fully seated against the hub flange. 5. Back off the wheel nut (1) and remove the washers (3). 6. Install the brake rotor. 7. Install the brake caliper and bracket. 8. Install the tire and wheel assembly. 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 2161 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement ^ Tools Required J 6627-A Tie Rod Puller Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper and bracket. Hang the caliper and the bracket from the vehicle. DO NOT allow the caliper and the bracket to hang by the brake hose. 4. Remove the brake rotor. 5. Use the J 6627-A in order to extract the stud (1) from the hub (2). Installation Procedure 1. Install a replacement stud in the wheel hub. 2. Add enough washers (3) in order to draw the stud into the hub (2). 3. Install the wheel nut (1) with the flat side against the washers (3). Important: Fully seat the wheel stud against the hub flange (2). 4. Tighten the wheel nut (1) until the wheel stud is fully seated against the hub flange. 5. Back off the wheel nut (1) and remove the washers (3). 6. Install the brake rotor. 7. Install the brake caliper and bracket. 8. Install the tire and wheel assembly. 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions CAUTION: - Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. - Do not connect a jumper cable directly to the negative terminal of a discharged battery to prevent sparking and possible explosion of battery gases. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Maintenance > Jump Starting > System Information > Service Precautions > Page 2165 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. 1. Position the vehicle with the booster battery so that the jumper cables will reach. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose ends, or missing insulation. 2. Place an automatic transmission in PARK. If equipped with a manual transmission, place in NEUTRAL and block the wheels. 3. Turn OFF all electrical loads on both vehicles that are not needed. 4. Turn OFF the ignition on both vehicles. 5. Connect the red positive (+) cable to the battery positive (+) terminal (2) of the vehicle with the discharged battery. Use a remote positive (+) terminal if the vehicle has one. 6. Connect the red positive (+) cable to the positive (+) terminal (1) of the booster battery. Use a remote positive (+) terminal if the vehicle has one. 7. Connect the black negative (-) cable to the negative (-) terminal (3) of the booster battery. 8. The final connection is made to a heavy, unpainted metal engine part (4) of the vehicle with the discharged battery. This final attachment must be at least 46 cm (18 in) away from the dead battery. CAUTION: Do not connect a jumper cable directly to the negative terminal of a discharged battery to prevent sparking and possible explosion of battery gases. 9. Start the engine of the vehicle that is providing the boost. 10. Crank the engine of the vehicle with the discharged battery. NOTE: Never operate the starter motor more than 15 seconds at a time without pausing in order to allow it to cool for at least 2 minutes. Overheating will damage the starter motor. 11. The black negative (-) cable must be first disconnected from the vehicle that was boosted (4). 12. Disconnect the black negative (-) cable from the negative (-) terminal (3) of the booster battery. 13. Disconnect the red positive (+) cable from the positive (+) terminal (1) of the booster battery. NOTE: Do not let the cable end touch any metal. Damage to the battery and other components may result. 14. Disconnect the red positive (+) cable from the remote positive (+) terminal (2) of the vehicle with the discharged battery. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications Compression Check: Specifications No cylinder reading should be less than 689 kPa (100 psi) The lowest reading should not be less than 70 percent of the highest reading. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information > Specifications > Page 2171 Compression Check: Testing and Inspection Engine Compression Test - Tools Required J 38722 Compression Tester A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket. 1. Run the engine until it reaches normal operating temperature. The battery must be at or near full charge. 2. Turn the engine OFF. Important: Remove the Powertrain Control Module (PCM) and the ignition fuses from the I/P fuse block. 3. Disable the ignition. 4. Disable the fuel systems. 5. Remove the spark plugs from all the cylinders. 6. Remove the air duct from the throttle body. 7. Block the throttle plate in the open position. 8. Measure the engine compression, using the following procedure: 8.1. Firmly install J 38722 to the spark plug hole. 8.2. Have an assistant crank the engine through at least four compression strokes in the testing cylinder. 8.3. Check and record the readings on J 38722 at each stroke. 8.4. Disconnect J 38722. 8.5. Repeat the compression test for each cylinder. 9. Record the compression readings from all of the cylinders. - The lowest reading should not be less than 70 percent of the highest reading. - No cylinder reading should be less than 689 kPa (100 psi). 10. The following are examples of the possible measurements: - When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. - When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, or if the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. - When the compression is low on the first stroke and does not build up in the following strokes, or the addition of oil does not affect the compression, the valves may be the cause. - When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause. 11. Remove the block from the throttle plate. 12. Install the air duct to the throttle body. 13. Install the spark plugs. 14. Install the Powertrain Control Module (PCM) fuse. 15. Install the ignition fuse to the I/P fuse block. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Bearing > Component Information > Specifications Camshaft Bearing: Specifications Camshaft Bearing Inside Diameter .............................................................................................................................. 47.523-47.549 mm (1.871-1.872 in.) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket First Pass ............................................................................................................................................. ................................................ 100 Nm (74 ft. lbs.) Final Pass ........................................................... ............................................................................................................................................... 90 degrees Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair Lifter / Lash Adjuster: Service and Repair Valve Lifter Replacement Removal Procedure 1. Remove the left or the right valve rocker arm cover. 2. Remove the lower intake manifold. Important: Ensure that all the valve train parts are kept in order so that they can be reinstalled in their original locations and with the same mating surface:, as when removed. 3. Remove the rocker arm bolts, the valve rocker arms, the push rods and the push rod guide plates. 4. Remove the valve lifter guide bolts. 5. Remove the valve lifter guides. 6. Remove the valve lifters. 7. Clean all the gasket mating surfaces. 8. Clean the valve train parts. 9. Inspect the valve lifters and the cam lobes for wear. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair > Page 2182 1. Dip the valve lifters in prelude GM P/N 12345501 (Canadian P/N 992704) or equivalent. 2. Install the valve lifters to the same position the valve lifters were removed. 3. Install the valve lifter guides. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the valve lifter guide bolts. - Tighten the bolts to 30 Nm (22 ft. lbs.). 5. Install the push rod guide plates, the push rods, the valve rocker arms, and the bolts. 6. Install the lower intake manifold. 7. Install the left or the right valve rocker arm cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair Push Rod: Service and Repair Valve Rocker Arm and Push Rod Replacement - Tools Required J 45059 Torque Angle Meter Removal Procedure 1. Remove the valve rocker arm covers. 2. Remove the valve rocker arm bolts. Important: Place the parts on a clean surface. Store the components in order so they can be reassembled in the same location and with the same mating surfaces as when removed. 3. Remove the valve rocker arms. 4. Remove the valve rocker arm guide plate if all of the rocker arms are removed. 5. Remove the push rods. 6. (glean the push rods, the valve rocker arms, the bolts, and the guide plates in a suitable solution. 7. Clean the valve rocker arm bolts of all thread adhesive. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Push Rod > Component Information > Service and Repair > Page 2186 1. Use compressed air in order to blow oil out of the tapped holes in the cylinder head. 2. Lubricate the ends of the push rods with new engine oil. Install the push rods to the same position the push rods was removed from. 3. Install the valve rocker arm guide plates. 4. Install the valve rocker arms. Notice: Refer to Special Fastener Notice in Service Precautions. 5. Apply GM P/N 12345493 (Canadian P/N 10953488) threadlocker or equivalent to the rocker arm bolt threads Notice: Refer to Fastener Notice in Service Precautions. 6. Install the rocker arm bolts. Tighten 6.1. Tighten the bolts to 15 Nm (11 ft. lbs.). 6.2. Use the J 45059 to rotate the bolts an additional 90 degrees. 7. Install the valve rocker arm covers. 8. Inspect the valve train from noise. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement - Tools Required J 45059 Torque Angle Meter Removal Procedure 1. Remove the valve rocker arm covers. 2. Remove the valve rocker arm bolts. Important: Place the parts on a clean surface. Store the components in order so they can be reassembled in the same location and with the same mating surfaces as when removed. 3. Remove the valve rocker arms. 4. Remove the valve rocker arm guide plate if all of the rocker arms are removed. 5. Remove the push rods. 6. (glean the push rods, the valve rocker arms, the bolts, and the guide plates in a suitable solution. 7. Clean the valve rocker arm bolts of all thread adhesive. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Service and Repair > Page 2190 1. Use compressed air in order to blow oil out of the tapped holes in the cylinder head. 2. Lubricate the ends of the push rods with new engine oil. Install the push rods to the same position the push rods was removed from. 3. Install the valve rocker arm guide plates. 4. Install the valve rocker arms. Notice: Refer to Special Fastener Notice in Service Precautions. 5. Apply GM P/N 12345493 (Canadian P/N 10953488) threadlocker or equivalent to the rocker arm bolt threads Notice: Refer to Fastener Notice in Service Precautions. 6. Install the rocker arm bolts. Tighten 6.1. Tighten the bolts to 15 Nm (11 ft. lbs.). 6.2. Use the J 45059 to rotate the bolts an additional 90 degrees. 7. Install the valve rocker arm covers. 8. Inspect the valve train from noise. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Connecting Rod Bearing Clearance ...................................................................................................................... 0.0127-0.0660 mm (0.0005-0.0026 inch) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 2195 Connecting Rod Bearing: Service and Repair Connecting Rod Bearing Replacement - Tools Required J 41507 Connecting Rod Assembly Guide - J 45059 Torque Angle Meter Removal Procedure 1. Remove the oil pan. 2. Remove the spark plugs from the cylinders that is being serviced. 3. Position the connecting rod to be serviced to bottom dead center (BDC) by rotating the crankshaft. 4. Remove the connecting rod cap bolts. 5. Remove the connecting rod cap and lower connecting rod bearing. Important: Keep the bearings with the original connecting rod and cap. Do this in order to reassemble the connecting rod. 6. Remove the lower connecting rod bearing from the connecting rod cap. 7. Install the J 41507 to the connecting rod. 8. Use the J 41507, in order to push up the connecting rod and piston and access the upper connecting rod bearing. 9. Remove the upper connecting rod bearing. 10. Wipe the oil from the bearings. 11. Inspect the connecting rod bearings. 12. Measure the bearing clearance. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 2196 Notice: Do not scrape, shim, or file bearing inserts. If the bearing surface of the insert is touched with bare lingers, the skin oil and acids will etch the bearing surface. Important: Make sure that the connecting rod cap bolt holes and the connecting rod cap mating surfaces are clean and dry. 1. Dip the connecting rod cap bolts in clean engine oil. 2. Use clean engine oil in order to lubricate the bearing surface. 3. Install the upper connecting rod bearing. 4. Use the J 41507, in order to pull down the piston, connecting rod and upper connecting rod bearing. 5. Remove the J 41507. 6. Install the lower connecting rod bearing to the connecting rod cap. 7. Install the connecting rod cap. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the connecting rod cap bolts. 8.1 Tighten the connecting rod cap bolts to 27 Nm (20 ft. lbs.). 8.2. Use the J 45059 to rotate the connecting rod cap bolts an additional 50 degrees. 9. Pry the connecting rod back and forth in order to check for binding. If necessary, loosen and then retighten the connecting rod cap bolts. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 2197 10. Measure the connecting rod side clearance. 11. Install the spark plugs to the cylinders. 12. Install the oil pan. 13. Inspect for proper oil pressure. 14. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair Crankshaft Seal Retainer: Service and Repair Crankshaft Rear Oil Seal and Housing Replacement - Tools Required J 45059 Torque Angle Meter - J 41349 Rear Cover Aligner Removal Procedure 1. Raise and support the vehicle. 2. Drain the cooling system. 3. Drain the engine oil. 4. Remove the engine flywheel. 5. Remove the oil pan. 6. Remove the crankshaft rear oil seal housing bolts. 7. Remove the crankshaft rear oil seal housing. 8. Remove the crankshaft rear oil seal. Important: Ensure not to damage the crankshaft outside diameter surface with any tool. 9. Remove the gasket from the crankshaft rear oil seal housing and the cylinder block. 10. Inspect the inside diameter of the bore. Correct or replace the crankshaft rear oil seal housing if necessary. 11. Inspect the crankshaft for nicks of burrs on the surface that contacts the seal. 12. Repair or replace the crankshaft if necessary. Installation Procedure 1. Ensure that the crankshaft rear oil seal is removed from the crankshaft rear oil seal housing. 2. Clean the old gasket from the crankshaft rear oil seal housing and the cylinder block. 3. Install the new gasket over the crankshaft rear oil seal housing bolt threads to aid in proper alignment of the gasket. Notice: Correct alignment of the housing is crucial to sealing lability of the rear main and the oil pan. Take care when installing the housing to ensure that the housing is properly aligned. Failure to follow these procedures may result in oil leaks. 4. Install the crankshaft rear oil seal housing and finger tighten all the bolts (loose enough to adjust the crankshaft rear oil seal housing) to hold the crankshaft rear oil seal housing in place. Make sure the gasket is not higher than the crankshaft rear oil seal housing. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Seal Retainer > Component Information > Service and Repair > Page 2201 Plastic inserts in the crankshaft rear oil seal housing are only used as an assembly aid and are not required for service. 5. Wipe a thin film of oil on both sides of the J 41349 to aid in installation and removal from the crankshaft. 6. Install the J 41349 over the crankshaft. Twisting or turning the J 41349 aids in sliding it completely over the crankshaft. 7. Place a straight edge on the cylinder block oil pan flange and the rear oil seal housing flange. Use a feeler gage to make sure that there is no more than 0.1016 mm (0.004 inch) step (high or low) on each side. Rotate the crankshaft rear oil seal housing to get the step equal on each side, if necessary. If the crankshaft rear oil seal housing can not be rotated to get the step within specification, replace the crankshaft rear oil seal housing. Notice: Refer to Fastener Notice in Service Precautions. 8. Tighten the crankshaft rear oil seal housing bolts. 8.1. Tighten the crankshaft rear oil seal housing bolts to 15 Nm (11 ft. lbs.). 8.2. Use the J 45059 to rotate the crankcase rear oil seal housing bolts an additional 50 degrees. 9. Remove the J 41349. 10. Recheck the step height on each side to make sure that the crankshaft rear oil seal housing did not move while tightening the bolts. If the step height is beyond specification, repeat steps 4 through 8 and measure again. If excessive clearance is still present, replace the crankshaft rear oil seal housing. 11. Install the new crankshaft rear oil seal. 12. Install the oil pan. 13. Install the engine flywheel. 14. Lower the vehicle. 15. Fill the cooling system. 16. Fill the crankcase with engine oil. 17. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine > Component Information > Specifications Crankshaft: Specifications Crankshaft Main Journal Diameter ....................................................................................................................... 63.470-63.495 mm (2.4988-2.4998 inch) Crankshaft Main Journal Out-of-Round .................................................................................................................................... 0.00635 mm (0.00025 inch) Crankshaft Main Journal Taper ..................................................................................................................................................... 0.00889 mm (0.002 inch) Crankshaft Rear Flange Runout ........................................................................................................................................................... 0.05 mm (0.002 inch) Crankshaft Runout - from Main 2 & 3 to 1 & 4 ................................................................................................................................. 0.076 mm (0.003 inch) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater Engine Block Heater: Service and Repair Coolant Heater Coolant Heater Replacement (3.8L) Removal Procedure 1. Drain the cooling system. 2. Disconnect the coolant heater cord from the coolant heater. 3. Loosen the bolt at the coolant heater but do not remove. 4. Remove the coolant heater. 5. Remove and clean any burrs, compound, paint, or rough spots from the core plug hole. Installation Procedure 1. Apply a coat of GM P/N 12346004, (Canadian P/N 10953480) thread sealant with Teflon or equivalent to the O-ring and clean the surface of the plug opening. 2. Install the coolant heater by pushing tight to the block. 3. Install the coolant heater so the element is at the 9 o'clock position (2). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater > Page 2209 Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the coolant heater bolt until both locking wings draw tight against the inner wall of the engine block. - Tighten the bolt to 2 Nm (17 inch lbs.). Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. 5. Connect the coolant heater cord to the coolant heater. 6. Fill the cooling system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater > Page 2210 Engine Block Heater: Service and Repair Heater Cord Coolant Heater Cord Replacement (3.8L) Removal Procedure 1. Remove the coolant heater cord retainer from the upper radiator support. 2. Raise and support the vehicle. 3. Cut the coolant heater cord retaining straps from the engine wiring harness. 4. Disconnect the coolant heater cord from the coolant heater. 5. Lower the vehicle. 6. Remove the coolant heater cord from the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater > Component Information > Service and Repair > Coolant Heater > Page 2211 Installation Procedure Notice: The heater cord must not touch the engine, hot pipes, manifold, or any moving parts. Route the cord to the left front of the engine compartment securing with tie straps as necessary to prevent damage. 1. Install the coolant heater cord to the vehicle. 2. Raise the vehicle. 3. Connect the coolant heater cord to the coolant heater. 4. Install new retaining straps to the coolant heater cord and the engine wiring harness. 5. Lower the vehicle. 6. Install the coolant heater cord retainer to the upper radiator support. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Balancer Bolt First Pass ............................................................................................................................................. ................................................. 150 Nm (111 lb ft) Final Pass ............................................................ ............................................................................................................................................. 76 degrees Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2215 Harmonic Balancer - Crankshaft Pulley: Service and Repair Crankshaft Balancer Replacement - Tools Required J 37096 Flywheel Holder - J 38197-A Crankshaft Balancer Puller - J 45059 Torque Angle Meter Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the drive belt. 3. Raise and support the vehicle. 4. Remove the right front tire and wheel. 5. Remove the right engine splash shield retainers and the engine splash shield. 6. Remove the torque converter covers. 7. Install the J 37096 to prevent the flywheel from turning. 8. Remove the crankshaft balancer bolt and discard the bolt. Important: Do not separate the crankshaft pulley from the crankshaft balancer. Service the crankshaft pulley and the crankshaft balancer as an assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 2216 9. Install the J 38197-A. 10. Remove the crankshaft balancer. 11. Remove the J 38197-A. Installation Procedure 1. Coat the engine front cover seal contact area on the crankshaft balancer, and the seal surface with engine oil. 2. Install the crankshaft balancer. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the new crankshaft balancer bolt. Use the J 45059 to prevent the flywheel from turning. Tighten 1. Tighten the bolt to 150 Nm (111 lb ft). 2. Use the J 45059 to rotate the bolt an additional 76 degrees. 4. Remove the J 45059. 5. Install the torque converter covers. 6. Install the right engine splash shield and the engine splash shield retainers. 7. Install the right front tire and wheel. 8. Lower the vehicle. 9. Install the drive belt. 10. Connect the negative battery cable. 11. Perform the CKP system variation learn procedure. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Specifications Piston: Specifications Piston Diameter Production - S/C ................................................................................................................................................ 96.489-96.528 mm (3.7988-3.8003 inch) Production - Non S/C ........................................................................................................................................ 96.482-96.497 mm (3.7985-3.7991 inch) Piston Diameter Service Limit- Minimum - S/C .................................................................................................................................................. 96.434 mm (3.7966 inch) Service Limit - Minimum - Non S/C .......................................................................................................................................... 96.442 mm (3.7969 inch) Piston to Bore Clearance New - VIN K ......................................................................................................................................................... 0.010-0.051 mm (0.0004-0.0020 inch) Used - VIN K ........................................................................................................................................................ 0.050-0.091 mm (0.0020-0.0036 inch) Piston to Bore Clearance New - VIN 1 ................................................................................................................................................... -0.0207-0.0437 mm (-0.0008-0.0018 inch) Used VIN 1 ....................................................................................................................................................... 0.0193-0.0997 mm (0.0008-0.0039 inch) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Specifications Piston Ring: Specifications Piston Ring End Gap First Compression Ring ................................................................................................................................................. 0.25-0.46 mm (0.010-0.018 inch) Second Compression Ring ............................................................................................................................................ 0.58-0 84 mm (0.023-0.033 inch) Oil Control Ring ............................................................................................................................................................ 0.254-0.762 mm (0.010-0 030 inch) Piston Ring to Groove Clearance First Compression Ring ......................................................................................................................................... 0.033-0.079 mm (0.0013-0 0031 inch) Second Compression Ring .................................................................................................................................. 40 033-0.079 mm (0.0013-0 0031 inch) Piston Ring Thickness First Compression Ring ......................................................................................................................................... 1.176-1.197 mm (0.0463-0.0471 inch) Second Compression Ring .................................................................................................................................. 1.1476-1.497 mm (0.0581-0 0589 inch) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable.A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Remove the fuel injector sight shield. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Install the J 34730-1A to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2228 3. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gage. 7. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container. Open the bleed valve in order to bleed the fuel system pressure. 2. Place a shop towel under the fuel pressure gage in order to catch any remaining fuel spillage. 3. Remove the fuel pressure gage from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2229 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage RELIEF PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the fuel injector sight shield. 3. Loosen the fuel filler cap to relieve tank vapor pressure. 4. Connect the J 34730-1A to the fuel pressure connection. Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gage in order to avoid spillage. 5. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 6. Drain any fuel remaining in the fuel pressure gage into an approved container. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair Rocker Arm Assembly: Service and Repair Valve Rocker Arm and Push Rod Replacement - Tools Required J 45059 Torque Angle Meter Removal Procedure 1. Remove the valve rocker arm covers. 2. Remove the valve rocker arm bolts. Important: Place the parts on a clean surface. Store the components in order so they can be reassembled in the same location and with the same mating surfaces as when removed. 3. Remove the valve rocker arms. 4. Remove the valve rocker arm guide plate if all of the rocker arms are removed. 5. Remove the push rods. 6. (glean the push rods, the valve rocker arms, the bolts, and the guide plates in a suitable solution. 7. Clean the valve rocker arm bolts of all thread adhesive. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Service and Repair > Page 2233 1. Use compressed air in order to blow oil out of the tapped holes in the cylinder head. 2. Lubricate the ends of the push rods with new engine oil. Install the push rods to the same position the push rods was removed from. 3. Install the valve rocker arm guide plates. 4. Install the valve rocker arms. Notice: Refer to Special Fastener Notice in Service Precautions. 5. Apply GM P/N 12345493 (Canadian P/N 10953488) threadlocker or equivalent to the rocker arm bolt threads Notice: Refer to Fastener Notice in Service Precautions. 6. Install the rocker arm bolts. Tighten 6.1. Tighten the bolts to 15 Nm (11 ft. lbs.). 6.2. Use the J 45059 to rotate the bolts an additional 90 degrees. 7. Install the valve rocker arm covers. 8. Inspect the valve train from noise. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement (Left) Valve Rocker Arm Cover Replacement - Left Removal Procedure 1. Disconnect the negative battery cable. Remove the fuel injector sight shield. 2. Remove the left engine lift bracket bolt and the nut. 3. Remove the left engine lift bracket. 4. Remove the right engine mount strut bracket. 5. Remove the left spark plug wires from the left spark plugs. 6. Remove the left spark plug wire cover from the left valve rocker arm cover. 7. Remove the left valve rocker arm cover bolts. Important: If the valve rocker arm cover adheres to the cylinder head, remove the valve rocker arm cover by bumping the end of the valve rocker arm cover with palm of hand or with a soft rubber mallet. 8. Remove the left valve rocker arm cover. 9. Remove the left valve rocker arm cover gasket. 10. (,lean the valve rocker arm cover mating surfaces. 11. Clean the valve rocker arm cover bolts of all thread locking adhesive. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 2238 1. Install the new valve rocker arm cover gasket. Ensure that valve the rocker arm cover gasket is seated properly in the valve rocker arm cover groove. 2. Install the left valve rocker arm cover. 3. Apply thread lock compound GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the valve rocker arm cover bolt threads. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the left valve rocker arm cover bolts. - Tighten the bolts to 10 Nm (89 inch lbs.). 5. Install the left spark plug wire cover to the left valve rocker arm cover. 6. Install the left spark plug wires to the spark plugs. 7. Install the right engine mount strut bracket. 8. Install the left engine lift bracket. 9. Install the left engine lift bracket bolt and the nut. - Tighten the bolt and the nut to 30 Nm (22 ft. lbs.). 10. Install the fuel injector sight shield. 11. Connect the negative battery cable. 12. Check and fill crankcase as necessary. 13. Inspect for oil leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 2239 Valve Cover: Service and Repair Valve Rocker Arm Cover Replacement (Right) Valve Rocker Arm Cover Replacement - Right Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the fuel injector sight shield. 3. Remove the drive belt tensioner. 4. Remove the right side spark plug wires from the spark plugs. 5. Remove the right side engine lift bracket bolt and the nut. 6. Remove the right side engine lift bracket. 7. Remove the fuel injector sight shield bracket nuts. 8. Remove the fuel injector sight shield bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 2240 9. Remove the right side valve rocker arm cover bolts. Important: If the valve rocker arm cover adheres to the cylinder head, remove the valve rocker arm cover by bumping the end of the valve rocker arm cover with the palm of your hand or a soft rubber mallet. 10. Remove the right side valve rocker arm cover. 11. Remove the right side valve rocker arm cover gasket. 12. Clean the valve rocker arm cover mating surface. 13. Clean the valve rocker arm cover bolts of all thread locking adhesive. Installation Procedure 1. Install the new valve rocker arm cover gasket. Ensure that the valve rocker arm cover gasket is seated properly in the valve rocker arm cover groove. 2. Install the right side valve rocker arm cover. 3. Apply thread lock compound GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the valve rocker arm cover bolt threads. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the right valve rocker arm cover bolts. - Tighten the bolts to 10 Nm (89 inch lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Valve Rocker Arm Cover Replacement (Left) > Page 2241 5. Install the fuel injector sight shield bracket to the exhaust manifold studs. 6. Install the fuel injector sight shield bracket nuts. - Tighten the nuts to 30 Nm (22 ft. lbs.). 7. Install the right side engine lift bracket. 8. Install the right side engine lift bracket bolt and the nut. - Tighten the bolt and the nut to 30 Nm (22 ft. lbs.). 9. Install the right side spark plug wires to the spark plugs. 10. Install the drive belt tensioner. 11. Install the fuel injector sight shield. 12. Connect the negative battery cable. 13. Check and fill crankcase as necessary 14. Inspect for oil leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair Valve Spring: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement - Tools Required J 23590 Spark Plug Port Adapter - J 38606 Valve Spring Compressor - J 42863 Valve Stem Seal Installer Removal Procedure 1. Remove the left or the right valve rocker arm cover. Important: Rotate the engine so that the piston in the cylinder being worked on is at top dead center before removing the valve locks. This will eliminate the possibility of the valve accidentally falling inside the cylinder. 2. Remove the valve rocker arms and the push rods. 3. Remove the spark plug. 4. Install the J 23590 to the spark plug port and apply compressed air in order to hold the valves closed. 5. Install the J 38606 on the valve spring. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 2245 6. Compress the valve spring using the J 38606. 7. Remove the valve locks. 8. Remove the valve spring and cap. 9. Remove the valve stem oil seal. 10. Inspect the valve spring for bent, cracked, or broken parts. Replace the valve spring if damaged. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 2246 Important: Use hand pressure to install the valve stem oil seal. - The color of the replacement seal may not be the same color as the original seal. Install the seals in their correct location based on GM part and package description. Make sure that the seal is fully seated on the valve guide. 1. Place the oil seal over the stem until the seal begins to contact the valve guide. 2. Use the J 42863 to install the valve stem oil seal over the valve guide. 3. Install the J 38606 on the valve spring. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring > Component Information > Service and Repair > Page 2247 4. Compress the valve spring using the J 38606. 5. Install the valve spring and cap. 6. Install the valve locks. 7. Release the valve spring. Important: Ensure that the valve locks are seated. 8. Release the air pressure, and remove the J 23590. 9. Install the spark plug. 10. Install the push rods and the valve rocker arms. 11. Install the left or the right valve rocker arm cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics Drive Belt: Technical Service Bulletins Engine - Drive Belt Misalignment Diagnostics INFORMATION Bulletin No.: 08-06-01-008A Date: July 27, 2009 Subject: Diagnosing Accessory Drive Belt / Serpentine Belt Noise and Availability and Use of Kent-Moore EN-49228 Laser Alignment Tool - Drive Belt Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add a model year and update the Tool Information. Please discard Corporate Bulletin Number 08-06-01-008 (Section 06 - Engine). Background Several aftermarket companies offer laser alignment tools for accessory drive systems that can be very helpful in eliminating drive belt noise as a result of misaligned pulleys. Typically pricing ranges from $160 - $200. EN-49228 Laser Alignment Tool - Drive Belt The GM Tool program has now made available a competitive, simple to use and time-saving laser tool to assist in achieving precise alignment of the drive belt pulleys. This optional tool removes the guesswork from proper pulley alignment and may serve to reduce comebacks from: - Drive Belt Noise - Accelerated Drive Belt Wear - Drive Belt Slippage Instructions The instructions below are specific only to the truck Gen IV V-8 family of engines. These instructions are only for illustrative purposes to show how the tool may be used. Universal instructions are included in the box with the Laser Alignment Tool - Drive Belt. Caution - Do not look directly into the beam projected from the laser. - Use caution when shining the laser on highly polished or reflective surfaces. Laser safety glasses help reduce laser beam glare in many circumstances. - Always use laser safety glasses when using the laser. Laser safety glasses are not designed to protect eyes from direct laser exposure. 1. Observe and mark the serpentine belt orientation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2253 2. Remove the serpentine belt from the accessory drive system. 3. Install the tool onto the power steering pulley. Position the legs of the tool into the outer grooves of the pulley, farthest from the front of the engine. 4. Install the retaining cord around the pulley and to the legs of the tool. 5. Put on the laser safety glasses provided with the tool. 6. Depress the switch on the rear of the tool to activate the light beam. 7. Rotate the power steering pulley as required to project the light beam onto the crankshaft balancer pulley grooves. 8. Inspect for proper power steering pulley alignment. - If the laser beam projects onto the second rib or raised area (1), the pulleys are aligned properly. - If the laser beam projects more than one-quarter rib 0.9 mm (0.035 in) mis-alignment, adjust the position of the power steering pulley as required. - Refer to SI for Power Steering Pulley Removal and Installation procedures. 9. Install the serpentine belt to the accessory drive system in the original orientation. 10. Operate the vehicle and verify that the belt noise concern is no longer present. Tool Information Please visit the GM service tool website for pricing information or to place your order for this tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2254 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Engine - Drive Belt Misalignment Diagnostics > Page 2255 Drive Belt: Technical Service Bulletins Engine - Serpentine Drive Belt Wear Information Bulletin No.: 04-06-01-013 Date: April 29, 2004 INFORMATION Subject: Information on Serpentine Belt Wear Models: 2004 and Prior Passenger Cars and Trucks 2003-2004 and Prior HUMMER H2 All current GM vehicles designed and manufactured in North America were assembled with serpentine belts that are made with an EPDM material and should last the life of the vehicle. It is extremely rare to observe any cracks in EPDM belts and it is not expected that they will require maintenance before 10 years or 240,000 km (150,000 mi) of use. Older style belts, which were manufactured with a chloroprene compound, may exhibit cracks depending on age. However, the onset of cracking typically signals that the belt is only about halfway through its usable life. A good rule of thumb for chloroprene-based belts is that if cracks are observed 3 mm (1/8 in) apart, ALL AROUND THE BELT, the belt may be reaching the end of its serviceable life and should be considered a candidate for changing. Small cracks spaced at greater intervals should not be considered as indicative that the belt needs changing. Any belt that exhibits chunking should be replaced. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2256 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Technical Service Bulletins > Page 2257 Drive Belt: Description and Operation Drive Belt System Description The drive belt system consists of the following components: The drive belt - The drive belt tensioner - The crankshaft balancer pulley - The accessory drive components: The power steering pump - The generator - The A/C compressor - The water pump The drive belt system uses one belt. The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys. The drive belt is made of different types of rubbers-chloroprene or EPDM-and have different layers or plys containing either fiber cloth or cords for reinforcement. Both sides of the drive belt may be used to drive the different accessory drive components. When the back side of the drive belt is used to drive a pulley, the pulley is smooth. The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive components and the crankshaft. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt or the pulleys. It may be necessary to spray a small amount of water on the drive belt in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2260 Steps 1-15 Drive Belt Chirping Diagnosis Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2261 Drive Belt: Testing and Inspection Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mix-positioning the drive belt one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Steps 1-6 Drive Belt Excessive Wear Diagnosis Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2262 Drive Belt: Testing and Inspection Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2263 Drive Belt Falls Off Diagnosis Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2264 Drive Belt: Testing and Inspection Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, complete the diagnostic table, and if the noise is only heard when the drive belt is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Steps 1-8 Drive Belt Rumbling Diagnosis Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2265 Drive Belt: Testing and Inspection Drive Belt Chirping Drive Belt Chirping Diagnosis Diagnostic Aids The symptom may be intermittent due to moisture on the drive belt or the pulleys. It may be necessary to spray a small amount of water on the drive belt in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom cleaning the belt pulleys may be the probable solution. A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the chirping noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table. 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the noise is related to the drive belt. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it can be strings in the drive belt grooves from the accumulation of rubber dust. 6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a temporary repair. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2266 Steps 1-15 Drive Belt Chirping Diagnosis Drive Belt Excessive Wear Drive Belt Excessive Wear Diagnosis Diagnostic Aids Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application. Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off. Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off. Test Description Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2267 The numbers below refer to the step numbers on the diagnostic table. 2. The inspection is to verify the drive belt is correctly installed on all of the drive belt pulleys. Wear on the drive belt may be caused by mix-positioning the drive belt one groove on a pulley. 3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt. The drive belt ribs should match all of the grooves on all of the pulleys. 4. This inspection is to verify the drive belt is not contacting any parts of the engine or body while the engine is operating. There should be sufficient clearance when the drive belt accessory drive components load varies. The drive belt should not come in contact with an engine or a body component when snapping the throttle. Steps 1-6 Drive Belt Excessive Wear Diagnosis Drive Belt Falls Off Drive Belt Falls Off Diagnosis Diagnostic Aids If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment. An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly. If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys. 4. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure of that pulley. 5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the smooth surface of a pulley when the back side of the belt is used to drive the pulley. 6. Accessory drive component brackets that are bent or cracked will let the drive belt fall off. 7. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment from the bracket moving under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2268 Drive Belt Falls Off Diagnosis Drive Belt Rumbling Drive Belt Rumbling Diagnosis Diagnostic Aids Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. The drive belt may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom. If replacing the drive belt, complete the diagnostic table, and if the noise is only heard when the drive belt is installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom. 3. This test is to verify that the drive belt is causing the rumbling noise. Rumbling noise may be confused with an internal engine noise due to the similarity in the description. Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. Inspecting the drive belt is to ensure that it is not causing a the noise. Small cracks across the ribs of the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the belt. 5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt does not have a smooth surface for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2269 Steps 1-8 Drive Belt Rumbling Diagnosis Drive Belt Squeal Drive Belt Squeal Diagnosis Diagnostic Aids A loose or improper installation of a body component, a suspension component, or other items of the vehicle may cause the squeal noise. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the engine is not making the noise do not proceed further with this table 3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief period will verify the squeal noise is the drive belt or an accessory drive component. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. This test is to verify that an accessory drive component does not have a seized bearing. With the belt remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory drive components with the engine operating by varying the load on the components to verify that the components operate properly. 5. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which could cause a squeal noise. 6. This test is to verify that the drive belt is not too long, which would prevent the drive belt tensioner from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly and may be turning an accessory drive component in the wrong direction. 7. Misalignment of the pulleys may be caused from improper mounting of the accessory drive component, incorrect installation of the accessory drive Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2270 component pulley, or the pulley bent inward or outward from a previous repair. Test for a misalign pulley using a straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found refer to that accessory drive component for the proper installation procedure for that pulley. 8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle compare the pulley sizes. Steps 1-9 Drive Belt Squeal Diagnosis Drive Belt Vibration Drive Belt Vibration Diagnosis Diagnostic Aids The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components. Test Description The numbers below refer to the step numbers on the diagnostic table. 2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may cause a similar symptom such as the exhaust system, or the drivetrain. 3. This test is to verify that the drive belts or accessory drive components may be causing the vibration. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The drive belt may cause a vibration. While the drive belt is removed this is the best time to inspect the condition of the belt. 6. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was installed. 8. This step should only be performed if the fan is driven by the drive belt. Inspect the engine cooling fan for bent, twisted, loose, or cracked blades. Inspect the fan clutch for smoothness, ease of turning. Inspect for a bent fan shaft or bent mounting flange. 9. This step should only be performed if the water pump is driven by the drive belt. Inspect the water pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play. Compare the water pump with a known good water pump. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2271 10. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that accessory component causing it to vibrate. Steps 1-11 Drive Belt Vibration Diagnosis Drive Belt Whine Drive Belt Whine Diagnosis Diagnostic Aids The drive belt will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive components by varying their loads making sure they are operating to their maximum capacity. Such items but not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or the generator failing. Test Description The numbers below refer to the step numbers on the diagnostic table. 3. This test is to verify that the noise is being caused by the accessory drive components. When removing the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the drive belt removed. 4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings. The drive belt may have to be installed and the accessory drive components operated separately by varying their loads. Refer to the suspected accessory drive component for the proper inspection and replacement procedure. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Drive Belt Chirping > Page 2272 Steps 1-5 Drive Belt Whine Diagnosis Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2273 Drive Belt: Service and Repair version 1.0 This procedure is not covered in the cartool: Drive Belt Replacement (L32) Removal Procedure 1. Rotate the drive belt tensioner using a 15-mm box end wrench on the pulley nut. 2. Remove the drive belt. Installation Procedure Important: After the new drive belt is installed, make sure that the mark on the drive belt tensioner is within range, as indicated on the tensioner housing. 1. Lift or rotate the drive belt tensioner using a 15-mm box end wrench on the pulley nut. 2. Install the drive belt. 3. Make sure the drive belt is properly routed. 4. Make sure the drive belt tensioner is operating properly. *********************************************************************** Minimum specs I could not find: 3.4L No Flywheel Sequence Camshaft Bearing Cap torque and sequence Valve Clearance Oil pan sequence Oil pump sequence Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Testing and Inspection > Page 2274 throttle body sequence 3.8L No Flywheel Sequence Camshaft Bearing Cap torque and sequence Valve Clearance Oil pan sequence Oil pump sequence throttle body sequence Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection Steps 1-4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt Tensioner > Component Information > Testing and Inspection > Page 2278 Drive Belt Tensioner: Service and Repair Drive Belt Tensioner Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Drain the cooling system. 3. Remove the coolant recovery reservoir. 4. Remove the drive belt. 5. Remove the generator. 6. Remove the heater hose adapters with the heater hoses from the drive belt tensioner. 7. Remove the drive belt tensioner bolts. 8. Remove the drive belt tensioner. 9. If replacing the drive belt tensioner, remove the thermostat bypass upper and lower pipe assemblies. Installation Procedure 1. If replacing the drive belt tensioner, lubricate the thermostat bypass upper and lower pipe assembly seals with engine coolant and install the upper and lower pipe assemblies. 2. Install the drive belt tensioner. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the drive belt tensioner bolts. - Tighten the bolts to 50 Nm (37 ft. lbs.). 4. Install the heater hose adapters with the heater hoses to the drive belt tensioner. 5. Install the generator. 6. Install the drive belt. 7. Install the coolant recovery reservoir. 8. Fill the cooling system. 9. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Testing and Inspection Engine Mount: Testing and Inspection Engine Mount Inspection Important: Before replacing any engine mount due to suspected fluid loss, verify that the source of the fluid is the engine mount, not the engine or accessories. 1. Install the engine support fixture. Raise the engine to release the weight from the engine mount and create slight tension in the rubber. 2. Observe the engine mount while raising the engine. Replace the engine mount if the engine mount exhibits any of the following conditions: - The hard rubber surface is covered with heat check cracks. - The rubber is separated from the metal plate of the engine mount. - The rubber is split through the center of the engine mount. 3. If there is movement between the metal plate of the engine mount and its attaching points, lower the engine on the engine mount. Tighten the bolts or nuts attaching the engine mount to the frame or engine mount bracket. 4. For information on the transaxle mount, refer to Transmission and Drivetrain. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement Engine Mount: Service and Repair Engine Mount Bracket Replacement Engine Mount and Bracket Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the fuel injector sight shield. 3. Disconnect the intake air temperature (IAT) sensor electrical connector. 4. Remove the air inlet duct from the throttle body. 5. Remove the right and left engine mount struts. 6. Remove the drive belt. 7. Raise and support the vehicle. 8. Remove the right front tire and wheel. 9. Remove the right engine splash shield. 10. Remove the power steering oil cooler pipe brackets from the frame. 11. Remove the A/C compressor and the A/C compressor bracket. DO NOT discharge the A/C system. Secure the compressor. 12. Remove the right exhaust manifold pipe stud nuts from the catalytic converter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2284 13. Remove the engine mount lower nuts from the frame. 14. Lower the vehicle. 15. Install the engine support fixture. 16. Use the engine support fixture to raise the engine. 17. Raise the vehicle. 18. Remove the left engine mount bracket bolts from the engine. 19. Remove the right engine mount bracket bolts from the engine. 20. Support the frame with jackstands. 21. Loosen the left side frame bolts. Remove the right side frame bolts. Using the jackstands lower the frame for engine mount bracket removal. 22. Remove the engine mount bracket with the engine mount from the engine. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2285 23. Remove the engine mount upper nuts. 24. Remove the engine mount from the engine mount bracket. Installation Procedure 1. Install the engine mount to the engine mount bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount upper nuts to the engine mount and the engine mount bracket. - Tighten the engine mount upper nuts to 43 Nm (32 ft. lbs.). 3. Install the engine mount bracket with the engine mount to the engine. 4. Loosely install the right engine mount bracket bolts to the engine. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2286 5. Loosely install the left engine mount bracket bolts to the engine. - Tighten the left and the right engine mount bracket bolts to 102 Nm (75 ft. lbs.). 6. Using the jackstands raise the frame to the original position. 7. Install the right side frame bolts. - Tighten the right and the left side frame bolts to 180 Nm (133 ft. lbs.). 8. Lower the vehicle. 9. Use the engine support fixture to lower the engine. 10. Raise the vehicle. 11. Install the engine mount lower nuts to the frame. - Tighten the engine mount lower nuts to 43 Nm (32 ft. lbs.). 12. Install the catalytic converter to the right exhaust manifold. 13. Install the right exhaust manifold pipe stud nuts - Tighten the right exhaust manifold pipe stud nuts to 30 Nm (22 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2287 14. Install the A/C compressor bracket and the A/C compressor bracket bolts. - Tighten the A/C compressor bracket bolts to 50 Nm (37 ft. lbs.). 15. Install the A/C compressor and the A/C compressor nuts. - Tighten the A/C compressor nuts to 30 Nm (22 ft. lbs.). 16. Install the power steering oil cooler pipe brackets to the frame. 17. Install the right engine splash shield. 18. Install the right front tire and wheel. 19. Lower the vehicle. 20. Remove the engine support fixture. 21. Install the right and left engine mount struts. 22. Install the air inlet duct to the throttle body. 23. Connect the intake air temperature (IAT) sensor electrical connector. 24. Install the drive belt. 25. Install the fuel injector sight shield. 26. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2288 Engine Mount: Service and Repair Engine Mount Replacement Engine Mount and Bracket Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the fuel injector sight shield. 3. Disconnect the intake air temperature (IAT) sensor electrical connector. 4. Remove the air inlet duct from the throttle body. 5. Remove the right and left engine mount struts. 6. Remove the drive belt. 7. Raise and support the vehicle. 8. Remove the right front tire and wheel. 9. Remove the right engine splash shield. 10. Remove the power steering oil cooler pipe brackets from the frame. 11. Remove the A/C compressor and the A/C compressor bracket. DO NOT discharge the A/C system. Secure the compressor. 12. Remove the right exhaust manifold pipe stud nuts from the catalytic converter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2289 13. Remove the engine mount lower nuts from the frame. 14. Lower the vehicle. 15. Install the engine support fixture. 16. Use the engine support fixture to raise the engine. 17. Raise the vehicle. 18. Remove the left engine mount bracket bolts from the engine. 19. Remove the right engine mount bracket bolts from the engine. 20. Support the frame with jackstands. 21. Loosen the left side frame bolts. Remove the right side frame bolts. Using the jackstands lower the frame for engine mount bracket removal. 22. Remove the engine mount bracket with the engine mount from the engine. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2290 23. Remove the engine mount upper nuts. 24. Remove the engine mount from the engine mount bracket. Installation Procedure 1. Install the engine mount to the engine mount bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount upper nuts to the engine mount and the engine mount bracket. - Tighten the engine mount upper nuts to 43 Nm (32 ft. lbs.). 3. Install the engine mount bracket with the engine mount to the engine. 4. Loosely install the right engine mount bracket bolts to the engine. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2291 5. Loosely install the left engine mount bracket bolts to the engine. - Tighten the left and the right engine mount bracket bolts to 102 Nm (75 ft. lbs.). 6. Using the jackstands raise the frame to the original position. 7. Install the right side frame bolts. - Tighten the right and the left side frame bolts to 180 Nm (133 ft. lbs.). 8. Lower the vehicle. 9. Use the engine support fixture to lower the engine. 10. Raise the vehicle. 11. Install the engine mount lower nuts to the frame. - Tighten the engine mount lower nuts to 43 Nm (32 ft. lbs.). 12. Install the catalytic converter to the right exhaust manifold. 13. Install the right exhaust manifold pipe stud nuts - Tighten the right exhaust manifold pipe stud nuts to 30 Nm (22 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2292 14. Install the A/C compressor bracket and the A/C compressor bracket bolts. - Tighten the A/C compressor bracket bolts to 50 Nm (37 ft. lbs.). 15. Install the A/C compressor and the A/C compressor nuts. - Tighten the A/C compressor nuts to 30 Nm (22 ft. lbs.). 16. Install the power steering oil cooler pipe brackets to the frame. 17. Install the right engine splash shield. 18. Install the right front tire and wheel. 19. Lower the vehicle. 20. Remove the engine support fixture. 21. Install the right and left engine mount struts. 22. Install the air inlet duct to the throttle body. 23. Connect the intake air temperature (IAT) sensor electrical connector. 24. Install the drive belt. 25. Install the fuel injector sight shield. 26. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2293 Engine Mount: Service and Repair Engine Mount Strut Bracket Replacement - Left Engine Mount Strut Bracket Replacement - Left Removal Procedure 1. Drain the cooling system. 2. Remove the engine coolant temperature sensor. 3. Remove the engine mount strut at the left engine mount strut bracket. 4. Remove the engine mount strut bracket bolts. 5. Remove the engine mount strut bracket. Installation Procedure 1. Install the engine mount strut bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount strut bracket bolts. - Tighten the engine mount strut bracket bolts to 50 Nm (37 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2294 3. Install the engine mount strut to the left engine mount strut bracket. 4. Install the engine coolant temperature sensor. - Tighten the sensor to 25 Nm (18 ft. lbs.). 5. Fill the cooling system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2295 Engine Mount: Service and Repair Engine Mount Strut Bracket Replacement - Right Upper Engine Mount Strut Bracket Replacement - Right Upper Removal Procedure Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the fuel injector sight shield. 3. Remove the right engine mount strut at the upper engine mount strut bracket. 4. Remove the lower engine mount strut bracket nut. 5. Remove the lower engine mount strut bracket bolts and the lower engine mount strut bracket. 6. Remove the evaporative emission (EVAP) canister purge valve. 7. Relieve the fuel pressure. 8. Remove the fuel rail assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2296 9. Remove the upper engine mount strut bracket bolts. 10. Remove the upper engine mount strut bracket. Installation Procedure 1. Install the upper engine mount strut bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper engine mount strut bracket bolts. - Tighten the upper engine mount strut bracket bolts to 50 Nm (37 ft. lbs.). 3. Install the fuel rail assembly. 4. Install the evaporative emission (EVAP) canister purge valve. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2297 5. Install the lower engine mount strut bracket bolts. - Tighten the lower engine mount strut bracket bolts to 50 Nm (37 ft. lbs.). 6. Install the lower engine mount strut bracket nut. - Tighten the lower engine mount strut bracket nut to 30 Nm (22 ft. lbs.). 7. Install the right engine mount strut to the upper engine mount strut bracket. 8. Install the fuel injector sight shield. 9. Connect the negative battery cable. Lower Engine Mount Strut Bracket Replacement - Right Lower Removal Procedure Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the lower engine mount strut bracket bolts. 3. Remove the lower engine mount bracket nut. 4. Remove the lower engine mount bracket. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2298 1. Install the lower engine mount bracket to the exhaust manifold stud and the upper engine mount strut bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the lower engine mount strut bracket bolts. - Tighten the lower engine mount bracket bolts to 50 Nm (37 ft. lbs.). 3. Install the lower engine mount strut bracket nut. - Tighten the lower engine mount bracket nut to 30 Nm (22 ft. lbs.). 4. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2299 Engine Mount: Service and Repair Engine Mount Bracket Replacement Engine Mount and Bracket Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the fuel injector sight shield. 3. Disconnect the intake air temperature (IAT) sensor electrical connector. 4. Remove the air inlet duct from the throttle body. 5. Remove the right and left engine mount struts. 6. Remove the drive belt. 7. Raise and support the vehicle. 8. Remove the right front tire and wheel. 9. Remove the right engine splash shield. 10. Remove the power steering oil cooler pipe brackets from the frame. 11. Remove the A/C compressor and the A/C compressor bracket. DO NOT discharge the A/C system. Secure the compressor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2300 12. Remove the right exhaust manifold pipe stud nuts from the catalytic converter. 13. Remove the engine mount lower nuts from the frame. 14. Lower the vehicle. 15. Install the engine support fixture. 16. Use the engine support fixture to raise the engine. 17. Raise the vehicle. 18. Remove the left engine mount bracket bolts from the engine. 19. Remove the right engine mount bracket bolts from the engine. 20. Support the frame with jackstands. 21. Loosen the left side frame bolts. Remove the right side frame bolts. Using the jackstands lower the frame for engine mount bracket removal. 22. Remove the engine mount bracket with the engine mount from the engine. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2301 23. Remove the engine mount upper nuts. 24. Remove the engine mount from the engine mount bracket. Installation Procedure 1. Install the engine mount to the engine mount bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount upper nuts to the engine mount and the engine mount bracket. - Tighten the engine mount upper nuts to 43 Nm (32 ft. lbs.). 3. Install the engine mount bracket with the engine mount to the engine. 4. Loosely install the right engine mount bracket bolts to the engine. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2302 5. Loosely install the left engine mount bracket bolts to the engine. - Tighten the left and the right engine mount bracket bolts to 102 Nm (75 ft. lbs.). 6. Using the jackstands raise the frame to the original position. 7. Install the right side frame bolts. - Tighten the right and the left side frame bolts to 180 Nm (133 ft. lbs.). 8. Lower the vehicle. 9. Use the engine support fixture to lower the engine. 10. Raise the vehicle. 11. Install the engine mount lower nuts to the frame. - Tighten the engine mount lower nuts to 43 Nm (32 ft. lbs.). 12. Install the catalytic converter to the right exhaust manifold. 13. Install the right exhaust manifold pipe stud nuts - Tighten the right exhaust manifold pipe stud nuts to 30 Nm (22 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2303 14. Install the A/C compressor bracket and the A/C compressor bracket bolts. - Tighten the A/C compressor bracket bolts to 50 Nm (37 ft. lbs.). 15. Install the A/C compressor and the A/C compressor nuts. - Tighten the A/C compressor nuts to 30 Nm (22 ft. lbs.). 16. Install the power steering oil cooler pipe brackets to the frame. 17. Install the right engine splash shield. 18. Install the right front tire and wheel. 19. Lower the vehicle. 20. Remove the engine support fixture. 21. Install the right and left engine mount struts. 22. Install the air inlet duct to the throttle body. 23. Connect the intake air temperature (IAT) sensor electrical connector. 24. Install the drive belt. 25. Install the fuel injector sight shield. 26. Connect the negative battery cable. Engine Mount Replacement Engine Mount and Bracket Replacement Removal Procedure Caution: Refer to Battery Disconnect Caution in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2304 1. Disconnect the negative battery cable. 2. Remove the fuel injector sight shield. 3. Disconnect the intake air temperature (IAT) sensor electrical connector. 4. Remove the air inlet duct from the throttle body. 5. Remove the right and left engine mount struts. 6. Remove the drive belt. 7. Raise and support the vehicle. 8. Remove the right front tire and wheel. 9. Remove the right engine splash shield. 10. Remove the power steering oil cooler pipe brackets from the frame. 11. Remove the A/C compressor and the A/C compressor bracket. DO NOT discharge the A/C system. Secure the compressor. 12. Remove the right exhaust manifold pipe stud nuts from the catalytic converter. 13. Remove the engine mount lower nuts from the frame. 14. Lower the vehicle. 15. Install the engine support fixture. 16. Use the engine support fixture to raise the engine. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2305 17. Raise the vehicle. 18. Remove the left engine mount bracket bolts from the engine. 19. Remove the right engine mount bracket bolts from the engine. 20. Support the frame with jackstands. 21. Loosen the left side frame bolts. Remove the right side frame bolts. Using the jackstands lower the frame for engine mount bracket removal. 22. Remove the engine mount bracket with the engine mount from the engine. 23. Remove the engine mount upper nuts. 24. Remove the engine mount from the engine mount bracket. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2306 1. Install the engine mount to the engine mount bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount upper nuts to the engine mount and the engine mount bracket. - Tighten the engine mount upper nuts to 43 Nm (32 ft. lbs.). 3. Install the engine mount bracket with the engine mount to the engine. 4. Loosely install the right engine mount bracket bolts to the engine. 5. Loosely install the left engine mount bracket bolts to the engine. - Tighten the left and the right engine mount bracket bolts to 102 Nm (75 ft. lbs.). 6. Using the jackstands raise the frame to the original position. 7. Install the right side frame bolts. - Tighten the right and the left side frame bolts to 180 Nm (133 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2307 8. Lower the vehicle. 9. Use the engine support fixture to lower the engine. 10. Raise the vehicle. 11. Install the engine mount lower nuts to the frame. - Tighten the engine mount lower nuts to 43 Nm (32 ft. lbs.). 12. Install the catalytic converter to the right exhaust manifold. 13. Install the right exhaust manifold pipe stud nuts - Tighten the right exhaust manifold pipe stud nuts to 30 Nm (22 ft. lbs.). 14. Install the A/C compressor bracket and the A/C compressor bracket bolts. - Tighten the A/C compressor bracket bolts to 50 Nm (37 ft. lbs.). 15. Install the A/C compressor and the A/C compressor nuts. - Tighten the A/C compressor nuts to 30 Nm (22 ft. lbs.). 16. Install the power steering oil cooler pipe brackets to the frame. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2308 17. Install the right engine splash shield. 18. Install the right front tire and wheel. 19. Lower the vehicle. 20. Remove the engine support fixture. 21. Install the right and left engine mount struts. 22. Install the air inlet duct to the throttle body. 23. Connect the intake air temperature (IAT) sensor electrical connector. 24. Install the drive belt. 25. Install the fuel injector sight shield. 26. Connect the negative battery cable. Engine Mount Strut Bracket Replacement - Left Engine Mount Strut Bracket Replacement - Left Removal Procedure 1. Drain the cooling system. 2. Remove the engine coolant temperature sensor. 3. Remove the engine mount strut at the left engine mount strut bracket. 4. Remove the engine mount strut bracket bolts. 5. Remove the engine mount strut bracket. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2309 1. Install the engine mount strut bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine mount strut bracket bolts. - Tighten the engine mount strut bracket bolts to 50 Nm (37 ft. lbs.). 3. Install the engine mount strut to the left engine mount strut bracket. 4. Install the engine coolant temperature sensor. - Tighten the sensor to 25 Nm (18 ft. lbs.). 5. Fill the cooling system. Upper Engine Mount Strut Bracket Replacement - Right Upper Removal Procedure Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the fuel injector sight shield. 3. Remove the right engine mount strut at the upper engine mount strut bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2310 4. Remove the lower engine mount strut bracket nut. 5. Remove the lower engine mount strut bracket bolts and the lower engine mount strut bracket. 6. Remove the evaporative emission (EVAP) canister purge valve. 7. Relieve the fuel pressure. 8. Remove the fuel rail assembly. 9. Remove the upper engine mount strut bracket bolts. 10. Remove the upper engine mount strut bracket. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2311 1. Install the upper engine mount strut bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the upper engine mount strut bracket bolts. - Tighten the upper engine mount strut bracket bolts to 50 Nm (37 ft. lbs.). 3. Install the fuel rail assembly. 4. Install the evaporative emission (EVAP) canister purge valve. 5. Install the lower engine mount strut bracket bolts. - Tighten the lower engine mount strut bracket bolts to 50 Nm (37 ft. lbs.). 6. Install the lower engine mount strut bracket nut. - Tighten the lower engine mount strut bracket nut to 30 Nm (22 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2312 7. Install the right engine mount strut to the upper engine mount strut bracket. 8. Install the fuel injector sight shield. 9. Connect the negative battery cable. Lower Engine Mount Strut Bracket Replacement - Right Lower Removal Procedure Caution: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the lower engine mount strut bracket bolts. 3. Remove the lower engine mount bracket nut. 4. Remove the lower engine mount bracket. Installation Procedure 1. Install the lower engine mount bracket to the exhaust manifold stud and the upper engine mount strut bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the lower engine mount strut bracket bolts. - Tighten the lower engine mount bracket bolts to 50 Nm (37 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2313 3. Install the lower engine mount strut bracket nut. - Tighten the lower engine mount bracket nut to 30 Nm (22 ft. lbs.). 4. Connect the negative battery cable. Engine Mount Strut Bracket Replacement - Upper Radiator Support Engine Mount Strut Bracket Replacement - Upper Radiator Support Removal Procedure 1. Remove the engine mount struts from the engine mount strut brackets at the upper radiator support. 2. Remove the four bolts from the engine mount strut bracket to the upper radiator support. 3. Remove the engine mount strut bracket from the upper radiator support. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2314 1. Position the engine mount strut bracket over the upper radiator support so the engine mount strut bracket and the engine mount strut are aligned. Align the engine mount strut bracket with the proper holes of the upper radiator support. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four bolts through the engine mount strut bracket to the upper radiator support. - Tighten the engine mount strut bracket bolts at the upper radiator support to 28 Nm (21 ft. lbs.). 3. Install the engine mount struts to the engine mount strut brackets at the upper radiator support. Engine Mount Strut Replacement - Left Engine Mount Strut Replacement - Left Removal Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2315 1. Remove the bolt and the nut from the left engine mount strut at the left engine mount strut bracket on the engine. 2. Remove the bolt and the nut from the left engine mount strut at the left engine mount strut bracket on the upper radiator support. 3. Remove the engine mount strut. 4. Inspect the rubber in the engine mount strut for the following conditions: - Hardness - Splitting - Cracking Installation Procedure 1. Install the engine mount strut. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolt and the nut to the left engine mount strut at the left engine mount strut bracket on the upper radiator support. - Tighten the engine mount strut nut to 48 Nm (35 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2316 3. Position the P-clip to the left engine mount strut bracket bolt. Important: The engine mount strut bolt must always be installed as shown in the graphic. 4. Install the bolt and the nut to the left engine mount strut at the left engine mount strut bracket on the engine. - Tighten the engine mount strut nut to 48 Nm (35 ft. lbs.). Engine Mount Strut Replacement - Right Engine Mount Strut Replacement - Right Removal Procedure 1. Remove the bolt and the nut from the right engine mount strut at the right engine mount strut bracket on the engine. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2317 2. Remove the bolt and the nut from the right engine mount strut at the right engine mount strut bracket on the upper radiator support. 3. Remove the engine mount strut. 4. Inspect the rubber in the engine mount strut for the following conditions: - Hardness - Splitting - Cracking Installation Procedure 1. Install the engine mount strut. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolt and the nut to the right engine mount strut at the right engine mount strut bracket on the upper radiator support. - Tighten the engine mount strut nut to 48 Nm (35 ft. lbs.). 3. Install the bolt and the nut to the right engine mount strut at the right engine mount strut bracket on the engine. - Tighten the engine mount strut nut to 48 Nm (35 ft. lbs.). Installing Engine Support Fixture Engine Support Fixture - Tools Required J 28467-9OA Engine Support Adapters - J 28467-B Universal Engine Support Fixture Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2318 1. Raise the hood. 2. Disconnect the negative battery cable. 3. Remove the cross vehicle brace. 4. Remove the hood side rear seal from the pinch-weld flange (1). 5. Install the J 28467-9OA onto the strut attaching studs. 6. Install the strut tower support assemblies J 28467-5A over the J 28467-9OA. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2319 7. Install the wing nuts to the J 28467-9OA. 8. Install the strut tower tube J 28467-3 into the strut tower support assemblies J 28467-5A. 9. Install the 1/2 inch x 2.5 inch quick release pin J 28467-10 through the strut tower support assemblies J 28467-5A and the strut tower tube J 28467-3 on one side only. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2320 10. Install the radiator shelf tube J 28467-2A on the top of the strut tower tube J 28467-3 on the driver side. 11. Install the round tube of the front support assembly J 28467-4A through the large hole in the radiator shelf tube J 28467-2A. 12. Install the 7/16 inch x 2.0 inch quick release pin J 28467-9 through the hole in the front support assembly J 28467-4A in order to level the radiator shelf tube J 28467-2A. 13. Install the cross bracket assembly J 28467-1A. 14. Install the lift hook J 28467-7A through the lift hook bracket J 28467-6A. 15. Install the 1/2 inch lift hook washer and lift hook wing nut J 28467-34 onto the lift hook J 28467-7A. 16. Install the assembled lift hook bracket J 28467-6A over the passenger side radiator shelf tube J 28467-2A. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair > Engine Mount Bracket Replacement > Page 2321 17. Adjust the passenger side radiator shelf tube J 28467-2A and the assembled lift hook bracket J 28467-6A in order to align the hook with the left, rear of engine, lift hook bracket attached to the left exhaust manifold. 18. Install the lift hook J 28467-7A through the lift hook bracket J 28467-6A. 19. Install the 1/2 inch lift hook washer and lift hook wing nut J 28467-34 onto the lift hook J 28467-7A. 20. Install the assembled lift hook bracket J 28467-6A over the strut tower tube J 28467-3. 21. Adjust the assembled swivel lift hook bracket J 28467-8A in order to align the hook with the right, front of engine, lift hook bracket attached to the right exhaust manifold. 22. Hand tighten the cross bracket assembly J 28467-1A wing nuts. 23. Hand tighten the lift hook wing nuts J 28467-34 securely to remove all slack from the engine support fixture assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Drive Belt Idler Pulley - Upper Idler Pulley: Service and Repair Drive Belt Idler Pulley - Upper Drive Belt Idler Pulley Replacement - Upper Removal Procedure 1. Remove the supercharger drive belt. 2. Remove the idler pulley bolt. 3. Remove the drive belt idler pulley. Installation Procedure 1. Install the drive belt idler pulley. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Drive Belt Idler Pulley - Upper > Page 2326 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the idler pulley bolt. - Tighten the bolt to 50 Nm (37 ft. lbs.). 3. Install the supercharger drive belt. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Drive Belt Idler Pulley - Upper > Page 2327 Idler Pulley: Service and Repair Drive Belt Idler Pulley - Lower Drive Belt Idler Pulley Replacement - Lower Removal Procedure 1. Remove the supercharger drive belt. 2. Remove the idler pulley bolt. 3. Remove the drive belt idler pulley. Installation Procedure 1. Install the drive belt idler pulley. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the idler pulley bolt. - Tighten the bolt to 50 Nm (37 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Drive Belt Idler Pulley - Upper > Page 2328 3. Install the supercharger drive belt. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Drive Belt Idler Pulley - Upper > Page 2329 Idler Pulley: Service and Repair Drive Belt Idler Pulley Bracket Drive Belt Idler Pulley Bracket Replacement Removal Procedure 1. Remove the supercharger drive belt. 2. Remove the drive belt idler pulley bolt. 3. Remove the drive belt idler pulley. 4. Remove the idler pulley bracket bolts. 5. Remove the idler pulley bracket. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Idler Pulley > Component Information > Service and Repair > Drive Belt Idler Pulley - Upper > Page 2330 1. Install the drive belt idler pulley bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the idler pulley bracket bolts. - Tighten the bolts to 30 Nm (22 ft. lbs.). 3. Install the drive belt idler pulley. 4. Install the drive belt idler pulley bolt. - Tighten the bolt to 50 Nm (37 ft. lbs.). 5. Install the supercharger drive belt. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure - at 1850 RPM ................................................................................................................. ........................................................ 414 kPa (60 psi) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure > Component Information > Specifications > Page 2335 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing Low or No Oil Pressure The following conditions may cause low or no oil pressure: Low oil level Fill to the full mark on the oil level indicator. - Incorrect or malfunctioning oil pressure switch Replace the oil pressure switch. - Incorrect or malfunctioning oil pressure gage Replace the oil pressure gage. - Improper oil viscosity or diluted oil Install oil of proper viscosity for expected temperature. - Install new oil if the oil is diluted. - A worn or dirty oil pump Clean or replace the oil pump. - A plugged oil filter Replace the oil filter. - A loose or plugged oil pickup screen Replace the oil pickup screen. - A hole in the oil pickup tube Replace the oil pickup tube. - Excessive bearing clearance Replace the bearings. - Cracked, porous, or plugged oil gallery Repair or replace the engine block. - Missing or improperly installed gallery plugs Install or repair the plugs as needed. - A stuck pressure regulator valve Inspect the pressure regulator valve for sticking in the bore. - Inspect the bore for scoring and burrs. - A worn or poorly machined camshaft Replace the camshaft. - Worn valve guides Repair the valve guides as needed. Oil Pressure Testing - Tools Required J 25087-C Oil Pressure Tester If the vehicle has low oil pressure complete the following steps: 1. Inspect the oil level. 2. Raise and support the vehicle. 3. Remove the oil filter. 4. Assemble the plunger valve in the large hole of the J 25087-C base. Insert the hose in the small hole of the J 25087-C base. Connect the gage to the end of the hose. 5. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass valve. 6. Install the J 25087-C on the filter mounting pad. 7. Start the engine. 8. Inspect the overall oil pressure, the oil pressure switch, and for noisy lifters. Ensure that the engine is at operating temperature before inspecting the oil pressure. The oil pressure should be approximately 414 kPa (60 psi) at 1,850 RPM using 5W-30 engine oil. 9. If adequate oil pressure is indicated, test the oil pressure switch. 10. If a low reading is indicated, press the valve on the tester base in order to isolate the oil pump and/or its components from the lubricating system. An adequate reading at this time indicates a good pump and the previous low pressure was due to worn bearings, etc. A low reading while pressing the valve indicates a faulty pump. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Dip Stick - Dip Stick Tube > Component Information > Service and Repair Engine Oil Dip Stick - Dip Stick Tube: Service and Repair Oil Level Indicator and Tube Replacement Removal Procedure 1. Remove the oil level indicator. 2. Remove the oil level indicator tube bracket nut. 3. Remove the oil level indicator tube. Installation Procedure 1. Make sure that the O-ring is in place and install the oil indicator tube to the engine. 2. Install the oil indicator tube bracket to the exhaust manifold stud. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the oil level indicator tube bracket nut. - Tighten the nut to 19 Nm (14 ft. lbs.). 4. Install the oil level indicator. 5. Check and fill the engine oil as necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications Engine Oil: Technical Service Bulletins Engine - GM dexos 1 and dexos 2(R) Oil Specifications INFORMATION Bulletin No.: 11-00-90-001 Date: March 14, 2011 Subject: Global Information for GM dexos1(TM) and GM dexos2(TM) Engine Oil Specifications for Spark Ignited and Diesel Engines, Available Licensed Brands, and Service Fill for Adding or Complete Oil Change Models: 2012 and Prior GM Passenger Cars and Trucks Excluding All Vehicles Equipped with Duramax(TM) Diesel Engines GM dexos 1(TM) Information Center Website Refer to the following General Motors website for dexos 1(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 1(TM) Engine Oil Trademark and Icons The dexos(TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos‹›(TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos‹›(TM) specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 1(TM) engine oil. GM dexos 1(TM) Engine Oil Specification Important General Motors dexos 1(TM) engine oil specification replaces the previous General Motors specifications GM6094M, GM4718M and GM-LL-A-025 for most GM gasoline engines. The oil specified for use in GM passenger cars and trucks, PRIOR to the 2011 model year remains acceptable for those previous vehicles. However, dexos 1(TM) is backward compatible and can be used in those older vehicles. In North America, starting with the 2011 model year, GM introduced dexos 1(TM) certified engine oil as a factory fill and service fill for gasoline engines. The reasons for the new engine oil specification are as follows: - To meet environmental goals such as increasing fuel efficiency and reducing engine emissions. - To promote long engine life. - To minimize the number of engine oil changes in order to help meet the goal of lessening the industry's overall dependence on crude oil. dexos 1(TM) is a GM-developed engine oil specification that has been designed to provide the following benefits: - Further improve fuel economy, to meet future corporate average fuel economy (CAFE) requirements and fuel economy retention by allowing the oil to maintain its fuel economy benefits throughout the life of the oil. - More robust formulations for added engine protection and aeration performance. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2343 - Support the GM Oil Life System, thereby minimizing the replacement of engine oil, before its life has been depleted. - Reduce the duplication of requirements for a large number of internal GM engine oil specifications. International Lubricants Standardization and Approval Committee (ILSAC) GF-5 Standard In addition to GM dexos 1(TM), a new International Lubricants Standardization and Approval Committee (ILSAC) standard called GF-5, was introduced in October 2010. - There will be a corresponding API category, called: SN Resource Conserving. The current GF-4 standard was put in place in 2004 and will become obsolete in October 2011. Similar to dexos 1(TM), the GF-5 standard will use a new fuel economy test, Sequence VID, which demands a statistically significant increase in fuel economy versus the Sequence VIB test that was used for GF-4. - It is expected that all dexos 1(TM) approved oils will be capable of meeting the GF-5 standard. However, not all GF-5 engine oils will be capable of meeting the dexos 1(TM) specification. - Like dexos(TM), the new ILSAC GF-5 standard will call for more sophisticated additives. The API will begin licensing marketers during October 2010, to produce and distribute GF-5 certified products, which are expected to include SAE 0W-20, 0W-30, 5W-20, 5W-30 and 10W-30 oils. Corporate Average Fuel Economy (CAFE) Requirements Effect on Fuel Economy Since CAFE standards were first introduced in 1974, the fuel economy of cars has more than doubled, while the fuel economy of light trucks has increased by more than 50 percent. Proposed CAFE standards call for a continuation of increased fuel economy in new cars and trucks. To meet these future requirements, all aspects of vehicle operation are being looked at more critically than ever before. New technology being introduced in GM vehicles designed to increase vehicle efficiency and fuel economy include direct injection, cam phasing, turbocharging and active fuel management (AFM). The demands of these new technologies on engine oil also are taken into consideration when determining new oil specifications. AFM for example can help to achieve improved fuel economy. However alternately deactivating and activating the cylinders by not allowing the intake and exhaust valves to open contributes to additional stress on the engine oil. Another industry trend for meeting tough fuel economy mandates has been a shift toward lower viscosity oils. dexos 1(TM) will eventually be offered in several viscosity grades in accordance with engine needs: SAE 0W-20, 5W-20, 0W-30 and 5W-30. Using the right viscosity grade oil is critical for proper engine performance. Always refer to the Maintenance section of a vehicle Owner Manual for the proper viscosity grade for the engine being serviced. GM Oil Life System in Conjunction With dexos (TM) Supports Extended Oil Change Intervals To help conserve oil while maintaining engine protection, many GM vehicles are equipped with the GM Oil Life System. This system can provide oil change intervals that exceed the traditional 3,000 mile (4,830 km) recommendation. The dexos (TM) specification, with its requirements for improved oil robustness, compliments the GM Oil Life System by supporting extended oil change intervals over the lifetime of a vehicle. If all GM customers with GM Oil Life System equipped vehicles would use the system as intended, GM estimates that more than 100 million gallons of oil could be saved annually. GM dexos 2(TM) Information Center Website Refer to the following General Motors website for dexos 2(TM) information about the different licensed brands that are currently available: http://www.gmdexos.com GM dexos 2(TM) Engine Oil Trademark and Icons Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Engine - GM dexos 1 and dexos 2(R) Oil Specifications > Page 2344 The dexos (TM) specification and trademarks are exclusive to General Motors, LLC. Only those oils displaying the dexos (TM) trademark and icon on the front label meet the demanding performance requirements and stringent quality standards set forth in the dexos (TM)specification. Look on the front label for any of the logos shown above to identify an authorized, licensed dexos 2(TM) engine oil. GM dexos 2(TM) Engine Oil Specification - dexos 2(TM) is approved and recommended by GM for use in Europe starting in model year 2010 vehicles, regardless of where the vehicle was manufactured. - dexos 2(TM) is the recommended service fill oil for European gasoline engines. Important The Duramax(TM) diesel engine is the exception and requires lubricants meeting specification CJ-4. - dexos 2(TM) is the recommended service fill oil for European light-duty diesel engines and replaces GM-LL-B-025 and GM-LL-A-025. - dexos 2(TM) protects diesel engines from harmful soot deposits and is designed with limits on certain chemical components to prolong catalyst life and protect expensive emission reduction systems. It is a robust oil, resisting degradation between oil changes and maintaining optimum performance longer. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications Engine Oil: Capacity Specifications Engine Oil ............................................................................................................................................ ............................................................. 4.3L (4.5 Qt) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Capacity Specifications > Page 2347 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................................................. ........................................ Look for Starburst Symbol Above -18° C (0° F) ......................................... ......................................................................................................................................... 5W-30 or 10W-30 Below -20° C (-4° F) ............................................................................................................... .................................................... 5W-30 synthetic or 0W-30 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2348 Engine Oil: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. 2. Position the oil drain pan under the engine oil drain plug. 3. Remove the engine oil drain plug. 4. Clean and inspect the engine oil drain plug, repair or replace if necessary. 5. Clean and inspect the engine oil drain plug sealing surface on the oil pan, repair or replace oil pan if necessary. 6. Remove the oil filter. 7. Clean and inspect the oil filter sealing area on the oil filter adapter, repair or replace if necessary. Installation Procedure 1. Lightly oil the replacement oil filter gasket with clean oil and install the new oil filter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Specifications > Page 2349 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the new oil filter. - Tighten the new oil filter to 3/4 to 1 full turn, after the oil filter gasket contacts the oil filter mounting surface. 3. Install the engine oil pan drain plug. - Tighten the plug to 30 Nm (22 ft. lbs.). 4. Remove the oil drain pan. 5. Lower the vehicle. 6. Fill the engine with new engine oil. 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the oil indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, readjust the oil level by adding or draining the engine oil. 16. Check for oil leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement Oil Cooler: Service and Repair Engine Oil Cooler Hose/Pipe Replacement Engine Oil Cooler Hose/Pipe Replacement Removal Procedure 1. Remove the right engine splash shield. 2. Remove the support clip from the engine oil cooler lines. 3. Remove the engine oil cooler lines from the engine oil cooler. 4. Remove the engine oil cooler lines from the engine oil filter adapter. 5. Remove the engine oil cooler lines from the vehicle. Installation Procedure 1. Install the engine oil cooler lines to the vehicle. 2. Install the engine oil cooler lines to the engine oil cooler. 3. Install the engine oil cooler lines to the engine oil filter adapter. 4. Install the engine oil cooler line support clip to the engine oil cooler lines. 5. Install the right engine splash shield. 6. Add the proper amount of engine oil. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 2354 Oil Cooler: Service and Repair Engine Oil Cooler Pipe/Hose Quick Connect Fitting Engine Oil Cooler Pipe/Hose Quick Connect Fitting Removal Procedure 1. Using a bent-tip screwdriver or equivalent, pull on one of the open ends of the retaining ring in order to rotate the retaining ring. 2. Rotate the retaining ring around the quick connector until the retaining ring is out of position and can be completely removed. 3. Remove the engine oil cooler line from the quick connector fitting. Pull the lines straight out from the connector. 4. Clean all of the components in a suitable solvent, and dry them with compressed air. 5. Inspect the fittings, the connectors, the cooler lines, and the cooler for damage, distortion, or restriction. Replace parts as necessary. Installation Procedure Important: Do not install the new retaining ring onto the fitting by pushing the retaining ring down over the fitting. 1. Install the retaining ring into each quick connector fitting. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 2355 2. Hook one of the open ends of the retaining ring in one of the slots in the quick connector. 3. Rotate the retaining ring around the connector until the retaining ring is positioned with all 3 ears through the 3 slots. 4. Ensure the 3 retaining ring ears can be seen from the inside of the connector and the retaining ring can move freely in the slots. 5. Install the engine oil cooler line into the quick connector fitting. Pull back on the engine oil cooler lines to ensure a proper connection. 6. Inspect and fill the engine oil to the proper level. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 2356 Oil Cooler: Service and Repair Engine Oil Cooler Replacement - Auxiliary Engine Oil Cooler Replacement - Auxiliary Removal Procedure 1. Remove the radiator air baffle retainers. 2. Tilt the rear of the air baffle upward slightly. Slide the air baffle rearward in order to disengage the upper and lower clips of the air baffle from the fascia support. 3. Remove the radiator air baffle. 4. Remove the right engine splash shield. 5. Remove the support clip from the engine oil cooler lines 6. Reposition the hose clamps on the power steering cooler lines. 7. Remove the power steering oil cooler lines from the power steering cooler. 8. Remove the engine oil cooler lines from the engine oil cooler. 9. Remove the upper bolt (1) from the engine oil cooler/power steering cooler. 10. Remove the lower bolts (2) from the engine oil cooler/power steering cooler. 11. Remove the engine oil cooler/power steering cooler from the vehicle. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Cooler, Engine > Component Information > Service and Repair > Engine Oil Cooler Hose/Pipe Replacement > Page 2357 1. Install the engine oil cooler/power steering cooler to the vehicle. Notice: Refer to fastener Notice in Service Precautions. 2. Install the upper bolt (1) to the engine oil cooler/power steering cooler bracket. - Tighten the bolt to 2 Nm (18 inch lbs.). 3. Install the lower bolts (2) to the engine oil cooler/power steering cooler bracket. - Tighten the bolts to 2 Nm (18 inch lbs.). 4. Install the engine oil cooler lines to the engine oil cooler. 5. Install the power steering oil cooler lines to the power steering cooler. 6. Reposition the hose clamps on the power steering cooler lines. 7. Install the support clip to the engine oil cooler lines. 8. Install the right engine splash shield. 9. Position the radiator air baffle to the vehicle. Tilt the rear of the air baffle upward slightly. Position the upper clip of the air baffle to the lower edge of the front fascia support C-channel. 10. Slide the baffle towards the front of the vehicle in order to completely engage the upper and lower clips of the baffle onto the fascia support. 11. Align the tabs at the rear of the air baffle to the openings in the upper radiator support. 12. Install the radiator air baffle retainers. 13. Add the proper amount of engine oil and power steering fluid. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Engine - Noise/Damage Oil Filter Application Importance Oil Filter: Technical Service Bulletins Engine - Noise/Damage Oil Filter Application Importance INFORMATION Bulletin No.: 07-06-01-016B Date: July 27, 2009 Subject: Information on Internal Engine Noise or Damage After Oil Filter Replacement Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being updated to add model years. Please discard Corporate Bulletin Number 07-06-01-016A (Section 06 - Engine/Propulsion System). Important Engine damage that is the result of an incorrect or improperly installed engine oil filter is not a warrantable claim. The best way to avoid oil filter quality concerns is to purchase ACDelco(R) oil filters directly from GMSPO. Oil filter misapplication may cause abnormal engine noise or internal damage. Always utilize the most recent parts information to ensure the correct part number filter is installed when replacing oil filters. Do not rely on physical dimensions alone. Counterfeit copies of name brand parts have been discovered in some aftermarket parts systems. Always ensure the parts you install are from a trusted source. Improper oil filter installation may result in catastrophic engine damage. Refer to the appropriate Service Information (SI) installation instructions when replacing any oil filter and pay particular attention to procedures for proper cartridge filter element alignment. If the diagnostics in SI (Engine Mechanical) lead to the oil filter as the cause of the internal engine noise or damage, dealers should submit a field product report. Refer to Corporate Bulletin Number 02-00-89-002I (Information for Dealers on How to Submit a Field Product Report). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2362 Oil Filter: Service and Repair Engine Oil and Oil Filter Replacement Removal Procedure 1. Raise and support the vehicle. 2. Position the oil drain pan under the engine oil drain plug. 3. Remove the engine oil drain plug. 4. Clean and inspect the engine oil drain plug, repair or replace if necessary. 5. Clean and inspect the engine oil drain plug sealing surface on the oil pan, repair or replace oil pan if necessary. 6. Remove the oil filter. 7. Clean and inspect the oil filter sealing area on the oil filter adapter, repair or replace if necessary. Installation Procedure 1. Lightly oil the replacement oil filter gasket with clean oil and install the new oil filter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component Information > Technical Service Bulletins > Page 2363 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the new oil filter. - Tighten the new oil filter to 3/4 to 1 full turn, after the oil filter gasket contacts the oil filter mounting surface. 3. Install the engine oil pan drain plug. - Tighten the plug to 30 Nm (22 ft. lbs.). 4. Remove the oil drain pan. 5. Lower the vehicle. 6. Fill the engine with new engine oil. 7. Start the engine. 8. Inspect for oil leaks after engine start up. 9. Turn off the engine and allow the oil a few minutes to drain back into the oil pan. 10. Remove the oil level indicator from the oil indicator tube. 11. Clean off the indicator end of the oil level indicator with a clean paper towel or cloth. 12. Install the oil level indicator into the oil level indicator tube until the oil level indicator handle contacts the top of the oil level indicator tube. 13. Again, remove the oil level indicator from the oil level indicator tube keeping the tip of the oil level indicator down. 14. Check the level of the engine oil on the oil level indicator. 15. If necessary, readjust the oil level by adding or draining the engine oil. 16. Check for oil leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair Oil Filter Adapter: Service and Repair Oil Filter Adapter and Bypass Valve Assembly Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. 3. Remove the right side wheel drive shaft. 4. Disconnect the oil pressure sensor electrical connector. 5. Drain the engine oil and remove the oil filter. 6. If equipped with an external engine oil cooler remove the following: - Oil filter (2) - Engine oil cooler housing fitting (3) - Engine oil cooler housing (4) - Engine oil cooler housing O-ring (5) 7. Remove the oil filter adapter bolts. 8. Remove the following components: - Oil filter adapter - Oil filter adapter gasket - Oil pressure valve and spring 9. (glean the parts in a suitable solvent. Dry the parts. 10. Clean the oil filter adapter gasket mating surfaces. 11. Inspect the following areas: - The oil pressure valve and the valve bore for burrs - The spring for loss of tension, replace the spring if necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 2367 12. If replacing the oil filter adapter and valve assembly, remove the engine oil pressure sensor from the oil filter adapter and valve assembly. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. If replacing the oil filter adapter and valve assembly, install the engine oil pressure sensor to the oil filter adapter and valve assembly. - Tighten the sensor to 16 Nm (12 ft. lbs.). 2. Install the spring to the engine front cover. 3. Install the oil pressure valve to the engine front cover. 4. Install the oil filter adapter and a new gasket. 5. Install the oil filter adapter bolts. - Tighten the bolts to 15 Nm (11 ft. lbs.) + 50 degrees. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter Adapter > Component Information > Service and Repair > Page 2368 6. If equipped with an external engine oil cooler install the following: - Engine oil cooler housing O-ring (5) - Engine oil cooler housing (4) - Engine oil cooler housing fitting (3) - Tighten the fitting to 35 Nm (26 ft. lbs.). - Oil filter (2) 7. Install the engine oil filter and the engine oil drain plug. 8. Connect the oil pressure sensor electrical connector. 9. Install the right side wheel drive shaft. 10. Lower the vehicle. 11. Connect the negative battery cable. 12. Fill the crankcase with engine oil. 13. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Service and Repair Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the engine oil drain plug in order to drain the engine oil. 3. Disconnect the oil level sensor electrical connector. 4. Remove the engine oil level sensor from the oil pan. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the engine oil level sensor to the oil pan. - Tighten the sensor to 20 Nm (15 ft. lbs.). 2. Connect the oil level sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Service and Repair > Page 2372 3. Install the engine oil drain plug. - Tighten the plug to 30 Nm (22 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with engine oil. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor For ECM > Component Information > Locations > Page 2376 Lower Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor For ECM > Component Information > Locations > Page 2377 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor For ECM > Component Information > Locations > Page 2378 Engine Oil Level Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications Oil Pan: Specifications Oil Pan Bolt .......................................................................................................................................... .................................................... 14 Nm (125 lb in) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2382 Oil Pan: Service and Repair Oil Pan Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the fuel injector sight shield. 3. Remove the air cleaner intake duct. 4. Install the engine support fixture. 5. Raise and support the vehicle. 6. Remove the right exhaust manifold pipe stud nuts from the catalytic converter. 7. Drain the engine oil and remove the oil filter. 8. Disconnect the oil level sensor electrical connector. 9. Remove the oil level sensor wiring harness bolt and reposition the oil level sensor wiring harness. 10. Remove the engine mount lower nuts from the engine mount. 11. Lower the vehicle. 12. Use the engine support fixture to raise the engine. 13. Raise the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2383 14. Remove the left engine mount bracket bolts from the engine. 15. Remove the right engine mount bracket bolts from the engine. 16. Remove the engine mount upper nuts. 17. Remove the engine mount and the bracket from the frame. 18. Remove the torque converter covers. Notice: Remove the oil level sensor, located in the oil pan, before the oil pan is removed. The sensor may be damaged if the oil pan is removed first. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2384 19. Remove the oil level sensor. 20. Remove the oil pan bolts. 21. Remove the oil pan. 22. Remove the oil pump pipe screen assembly and the oil pan gasket. 23. Clean the following parts: - Oil pump screen mating surfaces - Oil pan flanges - Oil pan rail - Front cover - Rear main bearing cap - Threaded holes Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2385 Important: For aluminum oil pans, begin with step 4. For steel oil pans, skip steps 4 and 5. 1. For steel oil pans, apply a continuous bead 6.35 mm (0.25 in) thick of RTV sealer GM P/N 12378521 (Canadian P/N 88901148) to the topside of the new windage tray gasket. Apply the RTV sealant directly over the sealing bead. 2. Install the NEW windage tray gasket onto the engine. 3. Apply a continuous bead 6.35 mm (0.25 in) thick of RTV sealer GM P/N 12378521 (Canadian P/N 88901148) to the topside of the new windage tray gasket. Apply the RTV sealant directly over the sealing bead. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2386 4. For aluminum oil pans, apply a continuous bead 6.35 mm (0.25 in) thick of RTV sealer GM P/N 12378521 (Canadian P/N 88901148), ensuring that the sealer also completely fills the groove in the oil pan. 5. To ensure proper sealing, apply additional sealer at the four points called out in the illustration (1). 6. Install the oil pan and oil pan windage tray gasket - if applicable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2387 7. Install the oil pump pipe screen assembly. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the oil pump pipe screen bolts. Tighten Tighten the bolts to 15 Nm (11 lb ft). 9. Install the oil pan. 10. Clean the oil pan bolts and apply one drop of thread lock compound GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the oil pan bolt threads. Important: DO NOT overtighten bolts or damage to the oil pan may occur, resulting in an oil leak. 11. Install the oil pan bolts. Tighten Tighten the oil pan bolts to 14 Nm (125 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2388 12. Install the oil level sensor. Tighten Tighten the sensor to 20 Nm (15 lb ft). 13. Install the torque converter covers. 14. Install the engine mount and the bracket to the frame. 15. Install the engine mount upper nuts. Tighten Tighten the nuts to 43 Nm (32 lb ft). 16. Install the engine mount bracket to the engine. 17. Loosely install the right engine mount bracket bolts to the engine. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2389 18. Loosely install the left engine mount bracket bolts to the engine. Tighten Tighten the bolts to 102 Nm (75 lb ft). 19. Lower the vehicle. 20. Using the engine support fixture lower the engine. 21. Raise the vehicle. 22. Install the engine mount lower nuts. Tighten Tighten the nuts to 43 Nm (32 lb ft). 23. Install the oil level sensor wiring harness and the oil level sensor wiring harness bolt to the engine. Tighten Tighten the bolt to 10 Nm (89 lb in). 24. Connect the oil level sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Specifications > Page 2390 25. Install right exhaust manifold pipe stud nuts. Tighten Tighten the nuts to 30 Nm (22 lb ft). 26. Install the engine oil filter. 27. Lower the vehicle. 28. Remove the engine support fixture. 29. Install the right and left engine mount struts. 30. Install the air cleaner intake duct. 31. Fill the crankcase with engine oil. 32. Install the fuel injector sight shield. 33. Connect the negative battery cable. 34. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Lower Right Rear Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2394 Lower Right Rear Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender > Component Information > Locations > Page 2395 Engine Oil Pressure (EOP) Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the engine oil pressure switch electrical connector. 3. Remove the oil pressure switch. Installation Procedure Notice; Refer to Fastener Notice in Service Precautions. 1. Install the engine oil pressure switch. - Tighten the switch to 16 Nm (12 ft. lbs.). 2. Connect the engine oil pressure switch electrical connector. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pick Up/Strainer > Component Information > Service and Repair Oil Pick Up/Strainer: Service and Repair Oil Pump Pipe and Screen Assembly Replacement Removal Procedure Notice: Remove the oil level sensor, located in the oil pan, before the oil pan is removed. The sensor may be damaged if the oil pan is removed first. 1. Remove the oil pan. 2. Remove the oil pump screen bolts. 3. Remove the oil pump pipe and the screen. 4. Remove the oil pump pipe and screen gasket. 5. Clean the screen and housing with solvent and blow dry. 6. Inspect the oil pump pipe and the screen, replace if necessary. 7. Clean the gasket mating surface on the pipe flange and the cylinder block. Installation Procedure 1. Install the new oil pump pipe and screen gasket. 2. Install the oil pump pipe and screen. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the oil pump screen bolts. - Tighten the bolts to 15 Nm (11 ft. lbs.). 4. Install the oil pan. Notice: Do not run the engine until the oil pressure is tested. Running the engine without measurable oil pressure will cause extensive damage. Notice: Stop the engine and remove the oil pan if the oil pressure does not build up immediately. Check the oil pump pipe and the screen for a clogged screen, damaged pipe, or a damaged gasket. Running the engine without measurable oil pressure will cause extensive damage. 5. Inspect and verify that the oil pressure is within specifications. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications Engine Oil Pressure: Specifications Oil Pressure - at 1850 RPM ................................................................................................................. ........................................................ 414 kPa (60 psi) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil Pressure > Component Information > Specifications > Page 2406 Engine Oil Pressure: Testing and Inspection Oil Pressure Diagnosis and Testing Low or No Oil Pressure The following conditions may cause low or no oil pressure: Low oil level Fill to the full mark on the oil level indicator. - Incorrect or malfunctioning oil pressure switch Replace the oil pressure switch. - Incorrect or malfunctioning oil pressure gage Replace the oil pressure gage. - Improper oil viscosity or diluted oil Install oil of proper viscosity for expected temperature. - Install new oil if the oil is diluted. - A worn or dirty oil pump Clean or replace the oil pump. - A plugged oil filter Replace the oil filter. - A loose or plugged oil pickup screen Replace the oil pickup screen. - A hole in the oil pickup tube Replace the oil pickup tube. - Excessive bearing clearance Replace the bearings. - Cracked, porous, or plugged oil gallery Repair or replace the engine block. - Missing or improperly installed gallery plugs Install or repair the plugs as needed. - A stuck pressure regulator valve Inspect the pressure regulator valve for sticking in the bore. - Inspect the bore for scoring and burrs. - A worn or poorly machined camshaft Replace the camshaft. - Worn valve guides Repair the valve guides as needed. Oil Pressure Testing - Tools Required J 25087-C Oil Pressure Tester If the vehicle has low oil pressure complete the following steps: 1. Inspect the oil level. 2. Raise and support the vehicle. 3. Remove the oil filter. 4. Assemble the plunger valve in the large hole of the J 25087-C base. Insert the hose in the small hole of the J 25087-C base. Connect the gage to the end of the hose. 5. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass valve. 6. Install the J 25087-C on the filter mounting pad. 7. Start the engine. 8. Inspect the overall oil pressure, the oil pressure switch, and for noisy lifters. Ensure that the engine is at operating temperature before inspecting the oil pressure. The oil pressure should be approximately 414 kPa (60 psi) at 1,850 RPM using 5W-30 engine oil. 9. If adequate oil pressure is indicated, test the oil pressure switch. 10. If a low reading is indicated, press the valve on the tester base in order to isolate the oil pump and/or its components from the lubricating system. An adequate reading at this time indicates a good pump and the previous low pressure was due to worn bearings, etc. A low reading while pressing the valve indicates a faulty pump. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement Intake Manifold: Technical Service Bulletins Engine - Intake Manifold Inspection/Replacement INFORMATION Bulletin No.: 00-06-01-026C Date: February 03, 2010 Subject: Intake Manifold Inspection/Replacement After Severe Internal Engine Damage Models: 2010 and Prior Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 00-06-01-026B (Section 06 - Engine). When replacing an engine due to internal damage, extreme care should be taken when transferring the intake manifold to the new Goodwrench service engine long block. Internal damage may result in the potential discharge of internal engine component debris in the intake manifold via broken pistons and/or bent, broken, or missing intake valves. After removing the intake manifold from the engine, the technician should carefully inspect all of the cylinder head intake ports to see if the valve heads are still present and not bent. Usually when the valve heads are missing or sufficiently bent, internal engine component debris will be present to varying degrees in the intake port of the cylinder head. If this debris is present in any of the cylinder head intake ports, the intake manifold should be replaced. This replacement is required due to the complex inlet runner and plenum configuration of most of the intake manifolds, making thorough and complete component cleaning difficult and nearly impossible to verify complete removal of debris. Re-installation of an intake manifold removed from an engine with deposits of internal engine component debris may result in the ingestion of any remaining debris into the new Goodwrench service engine. This may cause damage or potential failure of the new service engine. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement > Page 2411 Intake Manifold: Technical Service Bulletins Engine - Redesigned Upper Intake Manifold and Gaskets Bulletin No.: 04-06-01-017 Date: May 26, 2004 INFORMATION Subject: New Upper Intake Manifold and Gasket Kits Models: 1995-1997 Buick Riviera 1995-2004 Buick Park Avenue 1996-2004 Buick Regal 1997-2004 Buick LeSabre 1998-1999 Chevrolet Lumina 1998-2004 Chevrolet Monte Carlo 2000-2004 Chevrolet Impala 1995-1996 Oldsmobile Ninety-Eight 1995-1999 Oldsmobile Eighty-Eight 1998-1999 Oldsmobile Intrigue 1995-2004 Pontiac Bonneville 1997-2003 Pontiac Grand Prix with 3.8L V6 Engine (VIN K - RPO L36) New upper intake manifold and gasket kits have been released. These new kits will provide the dealer with the ability to get exactly what is necessary for a correct repair. In addition some of the gaskets have been updated to a more robust design. Please reference the part numbers when ordering from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Engine - Intake Manifold Inspection/Replacement > Page 2412 Parts Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Technical Service Bulletins > Page 2413 Intake Manifold: Specifications Upper Intake Manifold ......................................................................................................................... ....................................................... 10 Nm (89 lb in) Lower Intake Manifold ......................................................................................................................... ........................................................ 15 Nm (11 lb ft) Throttle Body Bolt/Nut ......................................................................................................................... .................................................... 10 Nm (89 lb in) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement Intake Manifold: Service and Repair Lower Intake Manifold Replacement Intake Manifold Replacement - Lower Removal Procedure 1. Remove the upper intake manifold. 2. Remove the generator brace. 3. Remove the drive belt tensioner with the mounting bracket and the heater water bypass inlet pipe. 4. Remove the exhaust gas recirculation (EGR) outlet pipe bolt from the lower intake manifold. 5. Remove the radiator inlet hose from the water outlet housing. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 2416 6. Disconnect the engine coolant temperature (ECT) sensor electrical connector. 7. Remove the right upper engine mount strut bracket. 8. Remove the generator brace bracket bolts. 9. Remove the generator brace bracket. 10. Remove the lower intake manifold bolts. 11. Remove the lower intake manifold. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 2417 12. Remove the lower intake manifold seals. 13. Remove the lower intake manifold gaskets. 14. If replacing the lower intake manifold, remove the water outlet housing bolt and stud, the water outlet housing, the gasket and the thermostat. 15. If replacing the lower intake manifold, remove the ECT sensor. 16. Inspect the flatness of inlet flanges. 17. Clean the intake manifold mating surfaces. 18. Clean the intake manifold bolts and bolt holes of adhesive compound. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. If removed, install the ECT sensor. Tighten Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 2418 Tighten the ECT sensor to 25 Nm (18 lb ft). 2. If removed, install the thermostat, the gasket, and the water outlet housing. 3. Install the water outlet housing bolt and the stud. Tighten Tighten the bolt and stud to 27 Nm (20 lb ft). 4. Install the lower intake manifold gaskets. 5. Apply sealer GM P/N 12346286 (Canadian P/N 10953472) or equivalent to the ends of the intake manifold seals. 6. Install the lower intake manifold seals. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 2419 7. Install the lower intake manifold. 8. Install the lower intake manifold bolts (1-12). Apply thread lock compound GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the two hidden bolts and ensure they are installed. Tighten Tighten the lower intake manifold bolts in sequence to 15 Nm (11 lb ft). 9. Install the generator brace bracket. 10. Install the generator brace bracket bolts. Tighten Tighten the bolts to 50 Nm (37 lb ft). 11. Install the right upper engine mount strut bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 2420 12. Connect the ECT sensor electrical connector. 13. Install the radiator inlet hose to the water outlet housing. 14. Install the EGR outlet pipe to the lower intake manifold. 15. Install the EGR outlet pipe bolt to the lower intake manifold. Tighten Tighten the bolt to 29 Nm (21 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 2421 16. Install the drive belt tensioner. 17. Install the generator brace. 18. Install the upper intake manifold. 19. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 2422 Intake Manifold: Service and Repair Upper Intake Manifold Replacement Intake Manifold Replacement - Upper Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the fuel injector sight shield. 3. Remove the air cleaner intake duct. 4. Drain the cooling system. 5. Remove the right spark plug wires from the ignition control module and reposition. 6. Relieve the fuel pressure. 7. Remove the fuel rail assembly. 8. Remove the brake booster hose from the vacuum source manifold in the upper intake manifold. 9. Remove the exhaust gas recirculation valve (EGR) wiring harness heat shield nut, bolt and the EGR heat shield. 10. Remove the throttle body support bracket upper bolt. 11. Disconnect the electrical connectors from the following: ^ EVAP purge solenoid ^ Throttle position (T/P) sensor ^ Idle air control (IAC) valve ^ Manifold absolute pressure (MAP) sensor ^ Mass air flow (MAP) sensor 12. Remove the EVAP purge solenoid vacuum line from the throttle body. 13. Remove the accelerator and the cruise control cables with the bracket from the throttle body. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 2423 14. Remove the upper intake manifold bolts and stud. 15. Clean the upper intake manifold bolt threads. 16. Remove the upper intake manifold by lifting the back of the intake and sliding the manifold forward from the throttle body support bracket. 17. Remove the upper-to-lower intake manifold carrier gasket from the upper intake manifold. 18. If the upper intake manifold is being replaced, remove the following: ^ Throttle body assembly. ^ Manifold absolute pressure (MAP) sensor. ^ Positive crankcase ventilation (PCV) valve. ^ Vacuum source manifold. Installation Procedure 1. If the manifold was replaced install the following: ^ Vacuum source manifold. ^ Positive crankcase ventilation (PCV) valve. ^ Manifold absolute pressure (MAP) sensor. ^ Throttle body assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 2424 2. Install the upper-to-lower intake manifold carrier gasket to the upper intake manifold. 3. Carefully place the upper intake manifold onto the lower intake manifold. Ensure that the alignment pins in the upper intake manifold align with the holes in the lower intake manifold. 4. Install the upper intake manifold. 5. Apply thread lock compound GM P/N 12345382, (Canadian P/N 10953489) or equivalent, to the bolt threads before assembly. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the upper intake manifold bolts (1-10). Tighten Tighten the upper intake manifold bolts in sequence to 10 Nm (89 lb in). 7. Install the accelerator and the cruise control cables with the bracket to the throttle body. 8. Install the EVAP purge solenoid vacuum line to the throttle body. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service and Repair > Lower Intake Manifold Replacement > Page 2425 9. Connect the electrical connectors to the following: ^ Mass air flow (MAP) sensor ^ Manifold absolute pressure (MAP) sensor ^ Idle air control (IAC) valve ^ Throttle position (T/P) sensor ^ EVAP purge solenoid 10. Install the throttle body upper support bracket bolt. Tighten Tighten the bolt to 10 Nm (89 lb in). 11. Install the EGR valve wiring harness heat shield nut and the bolt. Tighten Tighten the nut and the bolt to 10 Nm (89 lb in). 12. Install the brake booster hose to the vacuum source manifold. 13. Install the fuel rail assembly. 14. Install the right spark plug wires. 15. Install the air cleaner intake duct. 16. Install the fuel injector sight shield. 17. Connect the negative battery cable. 18. Fill the cooling system. 19. Inspect for fluid or vacuum leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Engine - New Rear Main Seal/Special Tool Crankshaft Main Bearing Seal: Technical Service Bulletins Engine - New Rear Main Seal/Special Tool Bulletin No.: 04-06-01-021 Date: June 24, 2004 INFORMATION Subject: New Rear Main Seal and Special Tool for Installation Models A new crankshaft rear oil seal and installation tool have been released. This new seal requires that the rear main housing be removed from the vehicle in order to properly install the seal with the new tool. This information will also be updated within SI. Crankshaft Rear Oil Seal and Housing Removal 1. Remove oil pan assembly as outlined in the appropriate Service Information Manual. 2. Remove the crankshaft rear oil seal housing bolts. 3. Remove the crankshaft rear oil seal housing and gasket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Engine - New Rear Main Seal/Special Tool > Page 2431 4. Place the crankshaft rear oil seal housing face down on a clean surface and support with blocks of wood. 5. Use a suitable driving tool and hammer and lightly tap around the outer edge of the seal to remove it. 6. Clean and inspect the crankshaft rear oil seal housing making sure it is free of any foreign material. 7. With all bolts removed from the housing, place it face up on a flat clean surface. Crankshaft Rear Oil Seal and Housing Installation ^ EN 47623 Rear Main Seal Installer ^ J 8092 Drive Handle ^ J 45059 Angle Meter Important: Do not apply or use any oil lubrication on the rear main oil seal, rear main oil seal housing or rear main seal installer EN 47623. Do not touch the sealing lip of the rear main oil seal once the protection sleeve is removed. Doing so will damage/deform the seal. Clean crankshaft sealing surface with a clean, lint free towel. Inspect lead-in edge of crankshaft for burrs/sharp edges that could damage the rear main oil seal. Remove burrs/sharp edges with crocus cloth before proceeding. 1. Carefully remove protection sleeve from new rear oil seal assembly. Important: Notice the direction of the rear oil seal. The new design seal is a reverse style as opposed to what has been used in the past. "THIS SIDE OUT" has been stamped into the seal as shown in the graphic. 2. Install the seal onto EN 47623 by placing the seal on an angle and using a twisting motion until it is fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Engine - New Rear Main Seal/Special Tool > Page 2432 3. Place EN 47623 along with J 8092 onto the housing as shown and apply a constant downward force until the seal is fully seated. Note: Do not use a sealant or adhesive when installing this component. Use of a sealant or adhesive can cause improper sealing. A component that is not sealed properly can leak leading to extensive engine damage. 4. Install the crankshaft rear oil seal housing gasket and housing onto the engine. Make sure to use a new oil seal housing gasket. Important: The plastic inserts in the crankshaft rear oil seal housing bolt holes are used to aid assembly only. The inserts are not required for service. 5. Install the crankshaft rear oil seal housing bolts and finger tighten. 6. Place a straight edge on the engine block oil pan flange and the crankshaft rear oil seal housing flange. Use a feeler gage to ensure there is no more than 0.10 mm (0.004 in) step on each side. If necessary, gently rotate the crankshaft rear oil seal housing to make the step equal on each side. Note: Refer to Fastener Notice on page P-7 in Cautions and Notices. 7. Tighten the crankshaft rear oil seal housing bolts. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Engine - New Rear Main Seal/Special Tool > Page 2433 Tighten: Tighten the crankshaft rear oil seal housing bolts to 15 N.m (11 lb ft). Use J 45059 to tighten the bolts an additional 50 degrees. 8. Recheck the step height on each side to ensure the crankshaft rear oil seal housing did not move. If the step height is beyond specification, reinstall the crankshaft rear oil seal housing and measure the step again. Replace the crankshaft rear oil seal housing if the clearance is still beyond specification. 9. Continue with oil pan installation as outlined in the Service Information Manual. Warranty Information: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Engine - New Rear Main Seal/Special Tool > Page 2434 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Page 2435 Crankshaft Main Bearing Seal: Service and Repair Crankshaft Rear Oil Seal Replacement - Tools Required J 381C16 Crankshaft Rear Oil Seal Installer Removal Procedure 1. Remove the engine flywheel. Important: Make sure not to damage the crankshaft Outside diameter surface or chamfer with the pry tool. 2. Remove the crankshaft rear oil seal. Insert a flat-bladed tool through the dust lip at an angle. Pry out the crankshaft rear oil seal by moving the handle of the tool towards the end of the crankshaft. Repeat as necessary around the crankshaft rear oil seal. 3. Inspect the inside diameter of the bore. Correct or replace the crankshaft rear oil seal housing as required. 4. Inspect the crankshaft for nicks or burrs on the surface that contacts the crankshaft rear oil seal. 5. Repair or replace the crankshaft if necessary. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Technical Service Bulletins > Page 2436 1. Apply engine oil to the inside and the outside diameter of the new crankshaft rear oil seal. Slide the new crankshaft rear oil seal over the mandrel until the back of the crankshaft rear oil seal bottoms squarely against the collar of the J 38196. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the crankshaft rear oil seal using the following steps: 2.1. Attach the J 38196 to the crankshaft by hand, or tighten the attaching screws. - Tighten the screws to 5 Nm (54 inch lbs.). 2.2. Turn the T-handle of the J 38196 so that the collar pushes the seal into the bore. Turn the handle until the collar is tight against the case. This will ensure that the crankshaft rear oil seal is seated properly between the crankshaft and the crankshaft rear oil seal housing. 2.3. Loosen the T-handle of J 38196 until it comes to a stop. This will ensure that the collar will be in the proper position for installing another new crankshaft rear oil seal. 2.4. Remove the attaching screws. 3. Install the engine flywheel. 4. Check and fill crankcase as necessary. 5. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Crankshaft Front Oil Seal Replacement - Tools Required J 35354-A Seal Installer Removal Procedure 1. Remove the crankshaft balancer. Important: Use care to avoid damaging the crankshaft front oil seal bore or the crankshaft front oil seal contact surfaces. 2. Pry out the crankshaft front oil seal with a flat-bladed tool such as a large screwdriver. 3. Inspect the crankshaft balancer and engine front cover for scratches. Installation Procedure 1. Install the crankshaft front oil seal in the engine front cover using the J 35354-A. 2. Tighten the bolt until the crankshaft front oil seal is seated in the engine front cover. 3. Remove the J 35354-A. 4. Install the crankshaft balancer. 5. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Engine - Redesigned Upper Intake Manifold and Gaskets Intake Manifold Gasket: Technical Service Bulletins Engine - Redesigned Upper Intake Manifold and Gaskets Bulletin No.: 04-06-01-017 Date: May 26, 2004 INFORMATION Subject: New Upper Intake Manifold and Gasket Kits Models: 1995-1997 Buick Riviera 1995-2004 Buick Park Avenue 1996-2004 Buick Regal 1997-2004 Buick LeSabre 1998-1999 Chevrolet Lumina 1998-2004 Chevrolet Monte Carlo 2000-2004 Chevrolet Impala 1995-1996 Oldsmobile Ninety-Eight 1995-1999 Oldsmobile Eighty-Eight 1998-1999 Oldsmobile Intrigue 1995-2004 Pontiac Bonneville 1997-2003 Pontiac Grand Prix with 3.8L V6 Engine (VIN K - RPO L36) New upper intake manifold and gasket kits have been released. These new kits will provide the dealer with the ability to get exactly what is necessary for a correct repair. In addition some of the gaskets have been updated to a more robust design. Please reference the part numbers when ordering from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Engine - Redesigned Upper Intake Manifold and Gaskets > Page 2444 Parts Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair Valve Guide Seal: Service and Repair Valve Stem Oil Seal and Valve Spring Replacement - Tools Required J 23590 Spark Plug Port Adapter - J 38606 Valve Spring Compressor - J 42863 Valve Stem Seal Installer Removal Procedure 1. Remove the left or the right valve rocker arm cover. Important: Rotate the engine so that the piston in the cylinder being worked on is at top dead center before removing the valve locks. This will eliminate the possibility of the valve accidentally falling inside the cylinder. 2. Remove the valve rocker arms and the push rods. 3. Remove the spark plug. 4. Install the J 23590 to the spark plug port and apply compressed air in order to hold the valves closed. 5. Install the J 38606 on the valve spring. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2448 6. Compress the valve spring using the J 38606. 7. Remove the valve locks. 8. Remove the valve spring and cap. 9. Remove the valve stem oil seal. 10. Inspect the valve spring for bent, cracked, or broken parts. Replace the valve spring if damaged. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2449 Important: Use hand pressure to install the valve stem oil seal. - The color of the replacement seal may not be the same color as the original seal. Install the seals in their correct location based on GM part and package description. Make sure that the seal is fully seated on the valve guide. 1. Place the oil seal over the stem until the seal begins to contact the valve guide. 2. Use the J 42863 to install the valve stem oil seal over the valve guide. 3. Install the J 38606 on the valve spring. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal > Component Information > Service and Repair > Page 2450 4. Compress the valve spring using the J 38606. 5. Install the valve spring and cap. 6. Install the valve locks. 7. Release the valve spring. Important: Ensure that the valve locks are seated. 8. Release the air pressure, and remove the J 23590. 9. Install the spark plug. 10. Install the push rods and the valve rocker arms. 11. Install the left or the right valve rocker arm cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair Oil Level Sensor: Service and Repair Engine Oil Level Sensor and/or Switch Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the engine oil drain plug in order to drain the engine oil. 3. Disconnect the oil level sensor electrical connector. 4. Remove the engine oil level sensor from the oil pan. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the engine oil level sensor to the oil pan. - Tighten the sensor to 20 Nm (15 ft. lbs.). 2. Connect the oil level sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Service and Repair > Page 2455 3. Install the engine oil drain plug. - Tighten the plug to 30 Nm (22 ft. lbs.). 4. Lower the vehicle. 5. Fill the crankcase with engine oil. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations > Page 2459 Lower Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations > Page 2460 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor For ECM > Component Information > Locations > Page 2461 Engine Oil Level Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Lower Right Rear Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2465 Lower Right Rear Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sender > Component Information > Locations > Page 2466 Engine Oil Pressure (EOP) Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the engine oil pressure switch electrical connector. 3. Remove the oil pressure switch. Installation Procedure Notice; Refer to Fastener Notice in Service Precautions. 1. Install the engine oil pressure switch. - Tighten the switch to 16 Nm (12 ft. lbs.). 2. Connect the engine oil pressure switch electrical connector. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket > Component Information > Specifications Camshaft Gear/Sprocket: Specifications Camshaft Sprocket First Pass ............................................................................................................................................. ................................................ 100 Nm (74 ft. lbs.) Final Pass ........................................................... ............................................................................................................................................... 90 degrees Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Timing Chain and Sprockets Replacement - Tools Required J 45059 Torque Angle Meter Removal Procedure 1. Remove the engine front cover. 2. Align the timing marks on the sprockets so that they are as close as possible. 3. Remove the timing chain dampener bolt. 4. Remove the timing chain dampener. 5. Remove the camshaft sprocket bolt. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2477 6. Remove the camshaft sprocket and the timing chain. Important: If the sprocket does not come off easily, a light blow on the lower edge of the sprocket with a plastic mallet should dislodge the sprocket. 7. Remove the crankshaft sprocket. 8. Remove the balance shaft drive gear in order to access the camshaft thrust plate, if required. 9. Remove the camshaft thrust plate bolts, if required. 10. Remove the camshaft thrust plate, if required. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2478 11. Remove the balance shaft driven gear bolt, if required. 12. Remove the balance shaft driven gear, if required. 13. Clean and inspect all of the components for wear and/or damage. 14. If the pistons have been moved in the engine, use the following procedure: 14.1. Turn the crankshaft so that the number one piston is at top dead center. 14.2. Turn the camshaft so that, with the sprocket temporarily installed, the timing mark is straight down. Installation Procedure 1. Install the balance shaft driven gear, if required. Notice: Refer to Fastener Notice in Service Precautions. Notice: Refer to Special Fastener Notice in Service Precautions. 2. Prevent the balance shaft from rotating and install the balance shaft driven gear bolt, if required. 2.1. Tighten the balance shaft driven gear bolt to 22 Nm (16 ft. lbs.). 2.2. Use the J 45059 to rotate the bolt an additional 70 degrees. 3. Install the camshaft thrust plate, if required. 4. Install the camshaft thrust plate bolts, if required. - Tighten the bolts to 15 Nm (11 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2479 5. Install the balance shaft drive gear. 6. Align the timing marks on the balance shaft drive gear and the balance shaft driven gear. 7. Install the crankshaft sprocket. 8. Install the timing chain and sprocket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2480 9. Assemble the timing chain on the sprockets with theta timing marks as close together as possible. 10. Install the camshaft sprocket bolt. 10.1. Tighten the bolt to 100 Nm (74 ft. lbs.). 10.2. Use the J 45059 to rotate the bolt an additional 90 degrees. 11. Install the timing chain dampener. 12. Install the timing chain dampener bolt. - Tighten the bolt to 22 Nm (16 ft. lbs.). Important: Rotate the engine two revolutions and check the timing marks. Ensure that the marks are aligned. 13. Install the engine front cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications Timing Cover: Specifications Engine Front Cover ............................................................................................................................................................. 20 Nm (15 ft. lbs.) + 40 degrees Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2484 Timing Cover: Service and Repair Engine Front Cover Replacement - Tools Required J 35354-A Seal Installer Removal Procedure 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. 3. Drain the engine oil. 4. Drain the cooling system. 5. Lower the vehicle. 6. Loosen the water pump pulley bolts. 7. Remove the drive belt tensioner. 8. Remove the water pump pulley. 9. Remove the power steering pump bolts and reposition the pump. 10. Raise the vehicle. 11. Remove the crankshaft balancer. Important: Be careful not to damage the crankshaft. 12. Pry out the crankshaft front oil seal with a flat-bladed tool such as a large screwdriver. Use care to avoid damaging the crankshaft front oil seal bore or the crankshaft front oil seal contact surfaces. 13. Disconnect the electrical connectors from the following: - Camshaft position (CAP) sensor - Crankshaft position (CKP) sensor - Oil pressure sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2485 14. Remove the crankshaft position sensor shield. 15. Remove the radiator outlet hose from the water pump. 16. Lower the vehicle. 17. Install the engine support fixture. 18. Raise the vehicle. Important: The oil pan can be dropped slightly for engine front cover clearance if all pan bolts are loosened and the oil level sensor is removed. 19. Remove the oil filter. 20. Remove the engine mount bracket for oil pan access. 21. Disconnect the oil level sensor electrical connector. 22. Remove the oil level sensor. 23. Remove the oil pan-to-engine front cover bolts. 24. Loosen the remaining oil pan bolts to gain access for the engine front cover removal. DO NOT remove the remaining oil pan bolts. 25. Remove the crankshaft position sensor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2486 26. Remove the engine front cover bolts. 27. Remove the engine front cover with the oil filter adapter as one assembly. 28. Remove the engine front cover gasket. 29. If replacing the engine front cover, remove the oil filter adapter and pressure relief valve from the engine front cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2487 30. If replacing the engine front cover, remove the water pump from the engine front cover. 31. If replacing the engine front cover, remove the oil pump cover and gear set from the engine front cover. 32. Inspect the oil pump cover and gear set. 33. If replacing the engine front cover, remove the camshaft position sensor from the engine front cover. 34. Inspect the timing chain for overall in and out movement. Maximum movement is 25.4 mm (1 inch). 35. Inspect the sprockets for wear. 36. Inspect the oil pan gasket. Replace the oil pan gasket if necessary. 37. Clean the engine front cover mating surfaces. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2488 1. If replacing the engine front cover, install the camshaft position sensor to the engine front cover. Notice; Refer to Fastener Notice in Service Precautions. 2. Install the camshaft position sensor bolt. - Tighten the bolt to 10 Nm (89 inch lbs.). 3. If replacing the engine front cover, install the oil pump cover and gear set to the engine front cover. 4. If replacing the engine front cover, install the water pump. 5. Install and tighten the water pump bolts. - Tighten the long water pump bolts to 34 Nm (25 ft. lbs.). - Tighten the short water pump bolts to 22 Nm (16 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2489 6. If replacing the engine front cover, install the pressure relief valve, the oil filter adapter and the oil filter adapter bolts to the engine front cover. - Tighten to 15 Nm (11 ft. lbs.) + 50 degrees. 7. Install the new engine front cover gasket. Ensure that the sealing surfaces are not damaged. 8. Apply sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the bolt threads. 9. Align the cogs on the crankshaft sprocket with the cogs on the oil pump gear set in the engine front cover. 10. Install the engine front cover to the engine. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2490 11. Install the engine front cover bolts (1-7). - Tighten the bolts to 20 Nm (15 ft. lbs.) + 40 degrees. 12. Install the crankshaft position sensor. 13. Install the crankshaft position sensor studs. - Tighten the studs to 30 Nm (22 ft. lbs.). 14. Install the oil pan-to-engine front cover bolts. - Tighten the oil pan bolts to 14 Nm (125 inch lbs.). 15. Install the oil level sensor. - Tighten the sensor to 20 Nm (15 ft. lbs.). 16. Connect the oil level sensor electrical connector. 17. Install the engine mount bracket. 18. Install the water pump pulley and bolts. - Tighten the bolts to 13 Nm (116 inch lbs.). 19. Install the radiator outlet hose to the water pump. 20. Install the oil filter. Install the engine oil pan drain plug. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Specifications > Page 2491 21. Install the new engine front cover seal using J 35354. 22. Tighten the bolt until the crankshaft front oil seal is seated in the engine front cover. 23. Remove the J 35354. 24. Install the crankshaft position sensor shield. 25. Connect the electrical connectors to the following: - Oil pressure sensor - Crankshaft position (CKP) sensor - Camshaft position (CMP) sensor 26. Install the crankshaft balancer. 27. Lower the vehicle. 28. Install the power steering pump and the bolts. - Tighten the bolts to 34 Nm (25 ft. lbs.). 29. Remove the engine support fixture. 30. Install the drive belt tensioner. 31. Fill the cooling system. 32. Fill the crankcase with engine oil. 33. Connect the negative battery cable. 34. Inspect for leaks. 35. Perform the CKP system variation learn procedure. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 364-405 kPa (53-59 psi) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable.A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Remove the fuel injector sight shield. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Install the J 34730-1A to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2498 3. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gage. 7. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container. Open the bleed valve in order to bleed the fuel system pressure. 2. Place a shop towel under the fuel pressure gage in order to catch any remaining fuel spillage. 3. Remove the fuel pressure gage from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2499 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST DESCRIPTION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2500 Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2501 Steps 4-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2502 Steps 8-9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2503 Steps 10-11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2504 Steps 12-15 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2505 Steps 16-17 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2506 Steps 18-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 2507 Steps 21-25 The numbers below refer to the step numbers on the diagnostic table. 2. This step verifies that the fuel pump is operating. 4. This step tests for an internal fuel leak. If the fuel pressure decreases during this test, an internal loss of pressure is indicated. 6. This step tests the fuel pressure regulator. The fuel pressure regulator is controlled by engine vacuum. With engine vacuum applied, the pressure should decrease by the specified value. 9. This step inspects the fuel pressure regulator for a fuel leak from the vacuum port. If fuel leaks from the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator. 10. This step tests for a loss of fuel pressure between the shut-off adapter on the fuel feed pipe and the fuel pump. 11. This step tests for a leaking fuel injector, or fuel pressure regulator. If the fuel pressure remains constant during this test, the fuel injectors are not leaking fuel. 14. This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, a restriction in the fuel return pipe is indicated. 16. This step determines if the fuel pressure regulator, or the fuel pump, is the cause of the low fuel pressure. If the pressure rises above the specified value, the fuel pump is OK. 18. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Inspect all fuel pump electrical circuits thoroughly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER INTAKE DUCT REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector (3). 2. Remove the IAT sensor with a twisting and pulling motion. 3. Loosen the air cleaner intake duct clamp. 4. Remove the air cleaner intake duct from the air cleaner cover. 5. Remove the air cleaner intake duct from the throttle body. INSTALLATION PROCEDURE 1. Install the air cleaner intake duct to the throttle body. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the air cleaner intake duct to the air cleaner cover. Tighten Tighten the air cleaner duct clamp to 2 N.m (18 lb in). 3. Install the IAT sensor. 4. Connect the IAT sensor electrical connector (3). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2523 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 2529 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 2530 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner intake duct . 2. Unclip the 2 air cleaner cover retaining clamps. 3. Remove the air cleaner housing cover (5). 4. Remove the air filter element (6). 5. Inspect the air cleaner housing cover (5), the seal assembly, and the air cleaner intake duct for damage. If a problem is found, replace as necessary. INSTALLATION PROCEDURE 1. Install the air filter element (6). 2. Install the air cleaner housing cover (5) and clip the housing cover retaining clamps. 3. Install the air cleaner intake duct. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable.A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Remove the fuel injector sight shield. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Install the J 34730-1A to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2536 3. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gage. 7. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container. Open the bleed valve in order to bleed the fuel system pressure. 2. Place a shop towel under the fuel pressure gage in order to catch any remaining fuel spillage. 3. Remove the fuel pressure gage from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 2537 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage RELIEF PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the fuel injector sight shield. 3. Loosen the fuel filler cap to relieve tank vapor pressure. 4. Connect the J 34730-1A to the fuel pressure connection. Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gage in order to avoid spillage. 5. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 6. Drain any fuel remaining in the fuel pressure gage into an approved container. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Refer to the list below for items to be inspected. 1. Inspect for correct routing of the spark plug wires. Improper routing may cause cross-firing. 2. Inspect each wire for any signs of cracks or splits in the wire. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal both the wire and the component connected to the wire should be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 2541 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT TOOLS REQUIRED J 38491 Spark Plug Boot Removal Tool REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Remove the spark plug wires (2, 4, 6) from the spark plugs at the rear of the engine using the following steps: 2.1. Note the position of the spark plug wires before removing the wires. 2.2. Twist the spark plug boot 1/2 turn before removing the boot. 2.3. Gently pry the heat shield up from spark plugs using the J 38491. 2.4. Remove the spark plug wire from the spark plugs at rear of the engine. 3. Remove the spark plug wires (1, 3, 5) from the spark plugs at the front of the engine using the following steps: 3.1. Note the position of the spark plug wires before removing the wires. 3.2. Twist the spark plug boot 1/2 turn before removing the boot. 3.3. Gently pry the heat shield up from spark plugs using the J 38491. 3.4. Remove the spark plug wires form the spark plugs at the front of the engine. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 2542 4. Remove the spark plug wires from the ignition coils. 5. Remove the spark plug wire retaining clips from the rear, front and top of the engine. 6. Remove the spark plug wires from the engine. 7. When replacing the spark plug wires transfer any of the following: - Boot heat shields - Spark plug wire conduit - Spark plug wire retaining clips INSTALLATION PROCEDURE 1. Position the spark plug wires to the engine. 2. Install the spark plug wire retaining clips from the rear, front and top of the engine. 3. Install the spark plug wires to the ignition coil in the proper position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 2543 4. Install the spark plug wires (1, 3, 5) to the spark plugs in the proper position at the front of the engine. 5. Install the spark plug wires (2, 4, 6) to the spark plugs in the proper position at the rear of the engine. 6. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark Plug Gap ................................................................................................................................... ..................................................... 0.060 in. (1.52 mm) Spark Plug Torque ........................................ ........................................................................................................................................ 11.0 lb. ft. (15.0 Nm) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2547 Spark Plug: Application and ID SPARK PLUG AC Delco P/N ...................................................................................................................................... .................................................................. 41-921 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2548 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION SPARK PLUG USAGE - Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. - Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2549 - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications . An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. - A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION - Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures - Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element Incorrect combustion - Reduced ignition system voltage output - Weak coils Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2550 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 2551 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wires from the spark plugs. 2. Remove the spark plugs from the engine. INSTALLATION PROCEDURE 1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to the gap specifications. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the spark plugs to the engine. Tighten If installing the spark plugs to a new cylinder tighten the plugs to 27N.m (20 lb ft). - If installing the spark plugs to an existing cylinder tighten the plugs to 15N.m(11 lb ft). 1. Connect the spark plug wires to the spark plugs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications No cylinder reading should be less than 689 kPa (100 psi) The lowest reading should not be less than 70 percent of the highest reading. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 2555 Compression Check: Testing and Inspection Engine Compression Test - Tools Required J 38722 Compression Tester A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket. 1. Run the engine until it reaches normal operating temperature. The battery must be at or near full charge. 2. Turn the engine OFF. Important: Remove the Powertrain Control Module (PCM) and the ignition fuses from the I/P fuse block. 3. Disable the ignition. 4. Disable the fuel systems. 5. Remove the spark plugs from all the cylinders. 6. Remove the air duct from the throttle body. 7. Block the throttle plate in the open position. 8. Measure the engine compression, using the following procedure: 8.1. Firmly install J 38722 to the spark plug hole. 8.2. Have an assistant crank the engine through at least four compression strokes in the testing cylinder. 8.3. Check and record the readings on J 38722 at each stroke. 8.4. Disconnect J 38722. 8.5. Repeat the compression test for each cylinder. 9. Record the compression readings from all of the cylinders. - The lowest reading should not be less than 70 percent of the highest reading. - No cylinder reading should be less than 689 kPa (100 psi). 10. The following are examples of the possible measurements: - When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. - When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, or if the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. - When the compression is low on the first stroke and does not build up in the following strokes, or the addition of oil does not affect the compression, the valves may be the cause. - When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause. 11. Remove the block from the throttle plate. 12. Install the air duct to the throttle body. 13. Install the spark plugs. 14. Install the Powertrain Control Module (PCM) fuse. 15. Install the ignition fuse to the I/P fuse block. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolt Large Bolt ............................................................................................................................................ ................................................. 34 Nm (25 ft. lbs.) Small Bolt ............................................................. .......................................................................................................................... 13 Nm (116 inch lbs.) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2559 Water Pump: Service and Repair Water Pump Replacement (3.8L) Removal Procedure 1. Drain the cooling system. 2. Loosen the water pump pulley bolts. 3. Remove the drive belt. 4. Remove the water pump pulley bolts. 5. Remove the water pump pulley. 6. Remove the power steering pump and reposition. 7. Remove the water pump bolts. 8. Remove the water pump. 9. Remove the water pump gasket. 10. Clean and inspect the water pump mating surfaces. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Specifications > Page 2560 1. Install the water pump gasket. 2. Install the water pump. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the water pump bolts. - Tighten the long water pump bolts to 34 Nm (25 ft. lbs.). - Tighten the short water pump bolts to 22 Nm (16 ft. lbs.). 4. Install the water pump pulley. 5. Install the water pump pulley bolts. - Tighten the bolts to 13 Nm (115 inch lbs.). 6. Install the power steering pump. 7. Install the drive belt. 8. Fill the cooling system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Coolant: Technical Service Bulletins Cooling System - DEX-COOL(R) Coolant Leak Detection Dye Bulletin No.: 05-06-02-002B Date: January 18, 2008 INFORMATION Subject: DEX-COOL(R) Coolant - New Leak Detection Dye J 46366 - Replaces J 29545-6 Models: 1996-2008 GM Passenger Cars and Light/Medium Duty Trucks* (including Saturn) 1997-2008 Isuzu T-Series Medium Duty Tilt Cab Models Built in Janesville and Flint 1999-2008 Isuzu N-Series Medium Duty Commercial Models with 5.7L or 6.0L Gas Engine 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X *EXCLUDING 2006 and Prior Chevrolet Aveo, Epica, Optra, Vivant and Pontiac Matiz, Wave Supercede: This bulletin is being revised to include additional model years. Please discard Corporate Bulletin Number 05-06-02-002A (Section 06 - Engine/Propulsion System). Leak detection dye P/N 12378563 (J 29545-6) (in Canada P/N 88900915) may cause DEX-COOL(R) coolant to appear green in a black vessel making it appear to be conventional (green) coolant. This may cause a technician to add conventional coolant to a low DEX-COOL(R) system thus contaminating it. The green DEX-COOL(R) appearance is caused by the color of the leak detection dye which alters the color of the DEX-COOL(R) coolant. A new leak detection dye P/N 89022219 (J 46366) (in Canada P/N 89022220) has been released that does not alter the appearance of the DEX-COOL(R) coolant. When adding the new leak detection dye the color of the DEX-COOL(R) coolant will not change. For detecting leaks on any system that uses DEX-COOL(R) leak detection dye P/N 89022219 (in Canada P/N 89022220) should be used. The new leak detection dye can be used with both conventional and DEX-COOL(R) coolant. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2566 Coolant: Technical Service Bulletins Cooling System - Coolant Recycling Information Bulletin No.: 00-06-02-006D Date: August 15, 2006 INFORMATION Subject: Engine Coolant Recycling and Warranty Information Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER Vehicles 2005-2007 Saab 9-7X Attention: Please address this bulletin to the Warranty Claims Administrator and the Service Manager. Supercede: This bulletin is being revised to adjust the title and Include Warranty Information. Please discard Corporate Bulletin Number 00-06-02-006C (Section 06 - Engine/Propulsion System). Coolant Reimbursement Policy General Motors supports the use of recycled engine coolant for warranty repairs/service, providing a GM approved engine coolant recycling system is used. Recycled coolant will be reimbursed at the GMSPO dealer price for new coolant plus the appropriate mark-up. When coolant replacement is required during a warranty repair, it is crucial that only the relative amount of engine coolant concentrate be charged, not the total diluted volume. In other words: if you are using two gallons of pre-diluted (50:50) recycled engine coolant to service a vehicle, you may request reimbursement for one gallon of GM Goodwrench engine coolant concentrate at the dealer price plus the appropriate warranty parts handling allowance. Licensed Approved DEX-COOL(R) Providers Important: USE OF NON-APPROVED VIRGIN OR RECYCLED DEX-COOL(R) OR DEVIATIONS IN THE FORM OF ALTERNATE CHEMICALS OR ALTERATION OF EQUIPMENT, WILL VOID THE GM ENDORSEMENT, MAY DEGRADE COOLANT SYSTEM INTEGRITY AND PLACE THE COOLING SYSTEM WARRANTY UNDER JEOPARDY. Shown in Table 1 are the only current licensed and approved providers of DEX-COOL(R). Products that are advertised as "COMPATIBLE" or "RECOMMENDED" for use with DEX-COOL(R) have not been tested or approved by General Motors. Non-approved coolants may degrade the Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2567 coolant system integrity and will no longer be considered a 5 yr/150,000 mile (240,000 km) coolant. Coolant Removal Services/Recycling The tables include all coolant recycling processes currently approved by GM. Also included is a primary phone number and demographic information. Used DEX-COOL(R) can be combined with used conventional coolant (green) for recycling. Depending on the recycling service and/or equipment, it is then designated as a conventional 2 yr/30,000 mile (50,000 km) coolant or DEX-COOL(R) 5 yr/150,000 mile (240,000 km) coolant. Recycled coolants as designated in this bulletin may be used during the vehicle(s) warranty period. DEX-COOL(R) Recycling The DEX-COOL(R) recycling service listed in Table 2 has been approved for recycling waste engine coolants (DEX-COOL) or conventional) to DEX-COOL(R) with 5 yr/150,000 mile (240,000 km) usability. Recycling Fluid Technologies is the only licensed provider of Recycled DEX-COOL(R) meeting GM6277M specifications and utilizes GM approved inhibitor packages. This is currently a limited program being monitored by GM Service Operations which will be expanded as demand increases. Conventional (Green) Recycling Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2568 Processes shown in the Table 3 are capable of recycling waste engine coolants (DEX-COOL(R) or conventional) to a conventional (green) coolant. Recycling conventional coolant can be accomplished at your facility by a technician using approved EQUIPMENT (listed by model number in Table 3), or by an approved coolant recycling SERVICE which may recycle the coolant at your facility or at an offsite operation. Refer to the table for GM approved coolant recyclers in either of these two categories. Should you decide to recycle the coolant yourself, strict adherence to the operating procedures is imperative. Use ONLY the inhibitor chemicals supplied by the respective (GM approved) recycling equipment manufacturer. Sealing Tablets Cooling System Sealing Tablets (Seal Tabs) should not be used as a regular maintenance item after servicing an engine cooling system. Discoloration of coolant can occur if too many seal tabs have been inserted into the cooling system. This can occur if seal tabs are repeatedly used over the service life of a vehicle. Where appropriate, seal tabs may be used if diagnostics fail to repair a small leak in the cooling system. When a condition appears in which seal tabs may be recommended, a specific bulletin will be released describing their proper usage. Water Quality The integrity of the coolant is dependent upon the quality of DEX-COOL(R) and water. DEX-COOL(R) is a product that has enhanced protection capability as well as an extended service interval. These enhanced properties may be jeopardized by combining DEX-COOL(R) with poor quality water. If you suspect the water in your area of being poor quality, it is recommended you use distilled or de-ionized water with DEX-COOL(R). "Pink" DEX-COOL(R) DEX-COOL(R) is orange in color to distinguish it from other coolants. Due to inconsistencies in the mixing of the dyes used with DEX-COOL(R), some batches may appear pink after time. The color shift from orange to pink does not affect the integrity of the coolant, and still maintains the 5 yr/150,000 mile (240,000 km) service interval. Back Service Only use DEX-COOL(R) if the vehicle was originally equipped with DEX-COOL(R). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Cooling System - DEX-COOL(R) Coolant Leak Detection Dye > Page 2569 Contamination Mixing conventional green coolant with DEX-COOL(R) will degrade the service interval from 5 yrs./150,000 miles (240,000 km) to 2 yrs./30,000 miles (50,000 km) if left in the contaminated condition. If contamination occurs, the cooling system must be flushed twice immediately and re-filled with a 50/50 mixture of DEX-COOL(R) and clean water in order to preserve the enhanced properties and extended service interval of DEX-COOL(R). After 5 years/150,000 miles (240,000 km) After 5 yrs/150,000 miles (240,000 km), the coolant should be changed, preferably using a coolant exchanger. If the vehicle was originally equipped with DEX-COOL(R) and has not had problems with contamination from non-DEX-COOL(R) coolants, then the service interval remains the same, and the coolant does not need to be changed for another 5 yrs/150,000 miles (240,000 km) Equipment (Coolant Exchangers) The preferred method of performing coolant replacement is to use a coolant exchanger. A coolant exchanger can replace virtually all of the old coolant with new coolant. Coolant exchangers can be used to perform coolant replacement without spillage, and facilitate easy waste collection. They can also be used to lower the coolant level in a vehicle to allow for less messy servicing of cooling system components. It is recommended that you use a coolant exchanger with a vacuum feature facilitates removing trapped air from the cooling system. This is a substantial time savings over repeatedly thermo cycling the vehicle and topping-off the radiator. The vacuum feature also allows venting of a hot system to relieve system pressure. Approved coolant exchangers are available through the GMDE (General Motors Dealer Equipment) program. For refilling a cooling system that has been partially or fully drained for repairs other than coolant replacement, the Vac-N-Fill Coolant Refill Tool (GE-47716) is recommended to facilitate removal of trapped air from the cooling system during refill. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Engine Cooling System ....................................................................................................................... ............................................... 11.0 liters (11.7 quarts) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2572 Coolant: Fluid Type Specifications ENGINE COOLANT The cooling system in your vehicle is filled with DEX-COOL engine coolant. This coolant is designed to remain in your vehicle for 5 years or 150,000 miles (240 000 km), whichever occurs first, if you add only DEX-COOL extended life coolant. A 50/50 mixture of clean, drinkable water and DEX-COOL coolant will: ^ Give freezing protection down to -34°F (-37°C). ^ Give boiling protection up to 265°F (129°C). ^ Protect against rust and corrosion. ^ Help keep the proper engine temperature. ^ Let the warning lights and gages work as they should. NOTICE: Using coolant other than DEX-COOL may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50 000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX-COOL (silicate-free) coolant in your vehicle. WHAT TO USE Use a mixture of one-half clean, drinkable water and one-half DEX-COOL coolant which won't damage aluminum parts. If you use this coolant mixture, you don't need to add anything else. CAUTION: Adding only plain water to your cooling system can be dangerous. Plain water, or some other liquid such as alcohol, can boil before the proper coolant mixture will. Your vehicle's coolant warning system is set for the proper coolant mixture. With plain water or the wrong mixture, your engine could get too hot but you would not get the overheat warning. Your engine could catch fire and you or others could be burned. Use a 50/50 mixture of clean, drinkable water and DEX-COOL coolant. NOTICE: If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. If you have to add coolant more than four times a year, check your cooling system. NOTICE: If you use the proper coolant, you do not have to add extra inhibitors or additives which claim to improve the system. These can be harmful. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement Coolant Line/Hose: Service and Repair Thermostat Bypass Pipes Replacement Thermostat Bypass Pipes Replacement - Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Partially drain the cooling system. 2. Remove the air cleaner intake duct. 3. Remove the LH engine mount strut. 4. Remove the spark plugs wires from the left side spark plugs. 5. Use the J 38185 to reposition the radiator inlet hose clamp from the water outlet housing. 6. Remove the radiator inlet hose from the water outlet housing. 7. Remove the heater outlet hose (2) from the thermostat bypass pipe. 8. Remove the throttle body inlet (3) and outlet (4) hoses from the thermostat bypass pipe. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 2577 9. Remove the thermostat bypass pipe nut. 10. Remove the thermostat bypass pipe hose and clamp from the thermostat bypass pipe. 11. Remove the thermostat bypass pipe bolt. 12. Remove the thermostat bypass pipe. Installation Procedure 1. Install the thermostat bypass pipe. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the thermostat bypass pipe bolt. - Tighten the bolt to 11 Nm (98 inch lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 2578 3. Install the thermostat bypass pipe hose and clamp to the thermostat bypass pipe. 4. Install the thermostat bypass pipe nut. - Tighten the nut to 25 Nm (18 ft. lbs.). 5. Install the heater outlet hose (2) and the clamp to the thermostat bypass pipe. 6. Install the throttle body inlet (3) and outlet (4) hoses and the clamps to the thermostat bypass pipe. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 2579 7. Install the radiator inlet hose to the water outlet housing. 8. Use the J 38185 to reposition and install the radiator inlet hose clamp to the water outlet housing. 9. Install the spark plugs wires to the left side spark plugs. 10. Install the LH engine mount strut. 11. Install the air cleaner intake duct. 12. Fill the cooling system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 2580 Coolant Line/Hose: Service and Repair Throttle Body Heater Hose Replacement - Inlet Throttle Body Heater Hose Replacement - Inlet Removal Procedure 1. Remove the air cleaner intake duct. 2. Partially drain the cooling system. 3. Remove the throttle body inlet hose clamp and the hose (3) from the coolant pipe. 4. Remove the throttle body inlet hose clamp and the hose (3) from the throttle body and the vehicle. Installation Procedure 1. Install the throttle body inlet hose (3) and the hose clamp to the throttle body. 2. Install the throttle body inlet hose (3) and the hose clamp to the coolant pipe. 3. Install the air cleaner intake duct. 4. Fill the cooling system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Line/Hose > Component Information > Service and Repair > Thermostat Bypass Pipes Replacement > Page 2581 Coolant Line/Hose: Service and Repair Throttle Body Heater Hose Replacement - Outlet Throttle Body Heater Hose Replacement - Outlet Removal Procedure 1. Remove the air cleaner intake duct. 2. Partially drain the cooling system. 3. Remove the throttle body outlet hose clamp and the hose (4) from the coolant pipe. 4. Remove the throttle body outlet hose clamp and the hose (4) from the throttle body and the vehicle. Installation Procedure 1. Install the throttle body outlet hose (4) and the hose clamp to the throttle body. 2. Install the throttle body outlet hose (4) and the hose clamp to the coolant pipe. 3. Install the air cleaner intake duct. 4. Fill the cooling system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Reservoir > Component Information > Service and Repair Coolant Reservoir: Service and Repair Coolant Recovery Reservoir Replacement Removal Procedure 1. Reposition the reservoir hose clamp (1). 2. Remove the reservoir hose from the radiator overflow neck. 3. Remove the coolant recovery reservoir nuts (2) from the shock tower studs. 4. Remove the coolant recovery reservoir (3) from the lower retainer and the shock tower studs. 5. Drain the coolant from the recovery reservoir in to a clean container. Installation Procedure 1. Install the coolant recovery reservoir (3) onto the lower retainer and the shock tower studs. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the coolant recovery reservoir nuts (2) to the shock tower studs. - Tighten the nuts to 3.3 Nm (29 inch lbs.). 3. Lubricate the reservoir hose with clean water. Route the hose to the radiator overflow neck fitting. 4. Install the coolant reservoir hose (1) to the overflow neck fitting. 5. Install the reservoir hose and clamp (1), with the clamp tabs at the 11 o'clock position, to the radiator overflow fitting on the radiator filler neck. The hose end must be flush against the radiator filler neck. Seat the clamp squarely between the radiator filler neck and the flared end of the fitting. 6. Fill the coolant recovery reservoir to the proper level. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Cooling Fan - Left Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Cooling Fan - Left > Page 2590 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2591 Radiator Cooling Fan Motor: Service and Repair Cooling Fan Motor Replacement - Electric - Tools Required J 38185 Hose Clamp Pliers Removal Procedure Caution: An electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan. Caution: To help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan blade or housing should always be replaced. Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. 1. Disconnect the negative battery cable. 2. Remove the right and the left engine mount struts. Refer to the following procedures: - Engine Mount Strut Replacement - Right - Engine Mount Strut Replacement - Left - Engine Mount Strut Replacement - Right - Engine Mount Strut Replacement - Left 3. Remove the air cleaner assembly. 4. Remove the transmission oil cooler lines from the retainer clip at the bottom of the cooling fan shroud. 5. Remove the cooling fan shroud bolts. 6. Remove the bolt that connects the fan shroud to the condenser hold down bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2592 7. Remove the radiator upper support brackets and bolts that connect to the fan shroud. 8. Disconnect the engine cooling fan motors electrical connector. 9. Remove the cooling fans electrical harness from the fan shroud clips. 10. Remove the cooling fan shroud. 11. Remove the engine cooling fan heat shield. 12. Remove the engine cooling fan blade nut. 13. Remove engine cooling fan blade. Caution: If a fan blade is bent or damaged in any way, do not repair or reuse the damaged part. Always replace a bent or damaged fan blade. Fan blades that have been damaged can not be assured of proper balance and could fail and fly apart during subsequent use. This creates an extremely dangerous situation. The fan blades must remain in proper balance. You cannot assure fan blade balance once a fan blade has been bent or damaged. A fan blade that is not in proper balance could fail and fly apart during use, creating an extremely dangerous situation. 14. Inspect the cooling fan blades for the following conditions: - Bent or cracked cooling fan blades - Smoothness of the cooling fan blade mating surfaces - Remove burrs or other imperfections as necessary Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2593 15. Remove the engine cooling fan motor bolts. 16. Remove the engine cooling fan motor from the fan shroud. Installation Procedure 1. Install the engine cooling fan motor to the fan shroud. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine cooling fan motor bolts. - Tighten the bolts to 6 Nm (53 inch lbs.). 3. Install the engine cooling fan blade. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2594 4. Install the engine cooling fan blade nut. - Tighten the nut to 6 Nm (53 inch lbs.). 5. Install the engine cooling fan heat shield. Important: Ensure the lower edge of the fan shroud engages the clip at the bottom of the radiator. 6. Install the cooling fan shroud. 7. Install the cooling fan shroud bolts. - Tighten the bolts to 10 Nm (89 inch lbs.). 8. Install the cooling fans electrical harness to the fan shroud clips. 9. Connect the engine cooling fan motors electrical connector. 10. Install the bolt that connects the fan shroud to the condenser hold down bracket. - Tighten the bolts to 6 Nm (53 inch lbs.). 11. Install the radiator upper support brackets and bolts that connect to the fan shroud. - Tighten the bolts to 10 Nm (89 inch lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2595 12. Install the transmission oil cooler lines to the retainer clip at the bottom of the cooling fan shroud. 13. Install the air cleaner assembly. 14. Install the right and left engine mount struts. Refer to the following procedures: - Engine Mount Strut Replacement - Right - Engine Mount Strut Replacement - Left - Engine Mount Strut Replacement - Right - Engine Mount Strut Replacement - Left 15. Connect the negative battery cable. 16. Inspect for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2600 Engine Coolant Temperature (ECT) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2601 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Partially drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the thermostat housing. 3. Disconnect the ECT sensor electrical connector. 4. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. 1. Coat the threads with sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2602 3. Connect the ECT sensor electrical connector. 4. Install the thermostat housing. 5. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair Fan Shroud: Service and Repair Fan Shroud Replacement - Tools Required J 38185 Hose Clamp Pliers Removal Procedure Caution: An electric fan under the hood can start up even when the engine is not running and can injure you. Keep hands, clothing and tools away from any underhood electric fan. Caution: To help avoid personal injury or damage to the vehicle, a bent, cracked, or damaged fan blade or housing should always be replaced. Caution: Before servicing any electrical component, the ignition key must be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed otherwise in these procedures. If a tool or equipment could easily come in contact with a live exposed electrical terminal, also disconnect the negative battery cable. Failure to follow these precautions may cause personal injury and/or damage to the vehicle or its components. 1. Disconnect the negative battery cable. 2. Remove the right and the left engine mount struts. Refer to the following procedures: - Engine Mount Strut Replacement - Right - Engine Mount Strut Replacement - Left - Engine Mount Strut Replacement - Right - Engine Mount Strut Replacement - Left 3. Remove the air cleaner assembly. 4. Remove the transmission oil cooler lines from the retainer clip at the bottom of the cooling fan shroud. 5. Remove the cooling fan shroud bolts. 6. Remove the bolt that connects the fan shroud to the condenser hold down bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2606 7. Remove the radiator upper support brackets and bolts that connect to the fan shroud. 8. Disconnect the engine cooling fan motors electrical connector. 9. Remove the cooling fans electrical harness from the fan shroud clips. 10. Remove the cooling fan shroud. 11. Remove the engine cooling fan heat shield. 12. Remove the engine cooling fan blade nut. 13. Remove engine cooling fan blade. Caution: If a fan blade is bent or damaged in any way, do not repair or reuse the damaged part. Always replace a bent or damaged fan blade. Fan blades that have been damaged can not be assured of proper balance and could fail and fly apart during subsequent use. This creates an extremely dangerous situation. The fan blades must remain in proper balance. You cannot assure fan blade balance once a fan blade has been bent or damaged. A fan blade that is not in proper balance could fail and fly apart during use, creating an extremely dangerous situation. 14. Inspect the cooling fan blades for the following conditions: - Bent or cracked cooling fan blades - Smoothness of the cooling fan blade mating surfaces - Remove burrs or other imperfections as necessary Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2607 15. Remove the engine cooling fan motor bolts. 16. Remove the engine cooling fan motor from the fan shroud. Installation Procedure 1. Install the engine cooling fan motor to the fan shroud. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the engine cooling fan motor bolts. - Tighten the bolts to 6 Nm (53 inch lbs.). 3. Install the engine cooling fan blade. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2608 4. Install the engine cooling fan blade nut. - Tighten the nut to 6 Nm (53 inch lbs.). 5. Install the engine cooling fan heat shield. Important: Ensure the lower edge of the fan shroud engages the clip at the bottom of the radiator. 6. Install the cooling fan shroud. 7. Install the cooling fan shroud bolts. - Tighten the bolts to 10 Nm (89 inch lbs.). 8. Install the cooling fans electrical harness to the fan shroud clips. 9. Connect the engine cooling fan motors electrical connector. 10. Install the bolt that connects the fan shroud to the condenser hold down bracket. - Tighten the bolts to 6 Nm (53 inch lbs.). 11. Install the radiator upper support brackets and bolts that connect to the fan shroud. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Fan Shroud > Component Information > Service and Repair > Page 2609 - Tighten the bolts to 10 Nm (89 inch lbs.). 12. Install the transmission oil cooler lines to the retainer clip at the bottom of the cooling fan shroud. 13. Install the air cleaner assembly. 14. Install the right and left engine mount struts. Refer to the following procedures: - Engine Mount Strut Replacement - Right - Engine Mount Strut Replacement - Left - Engine Mount Strut Replacement - Right - Engine Mount Strut Replacement - Left 15. Connect the negative battery cable. 16. Inspect for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 2614 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 2615 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement Heater Core: Service and Repair Heater Case/Cover Replacement HEATER CORE COVER REPLACEMENT REMOVAL PROCEDURE 1. Remove the RH Instrument Panel Closeout/Insulator panel. 2. Remove the LH Instrument Panel Closeout/Insulator panel. 3. Remove the floor carpet. 4. Remove the rear floor air outlet duct from the holes in the floor reinforcement. 5. Disconnect the rear floor air outlet duct from the heater air outlet cover. 6. Remove the rear floor air outlet duct. 7. Remove the heater air outlet cover screws (2). 8. Remove the heater air outlet cover heat stakes (1) with a small chisel. 9. Remove the heater air outlet cover from the HVAC module assembly. 10. Remove the heater core cover screws (2). 11. Remove the heater core cover heat stakes (1) with a small chisel. 12. Remove the heater core cover from the HVAC module assembly. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 2618 1. From the inside of the heater core cover, drill the dimples adjacent to the heat stakes using a 5.5 mm (7/32 in) drill bit. 2. Install the heater core cover to the HVAC module assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the heater core cover screws (2). Tighten Tighten all screws to 1.5 N.m (13 lb in). 4. From the inside of the heater air outlet cover, drill the dimples adjacent to the heat stakes using a 5.5 mm (7/32 in) drill bit. 5. Install the heater air outlet cover. 6. Install the heater air outlet cover screws (2). Tighten Tighten the screws to 1.5 N.m (13 lb in). 7. Connect the rear floor air outlet duct to the heater air outlet cover. 8. Install the rear floor air outlet duct to the holes in the floor reinforcement. 9. Install the floor carpet. 10. Install the RH Instrument Panel Closeout/Insulator panel. 11. Install the LH Instrument Panel Closeout/Insulator panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 2619 Heater Core: Service and Repair Heater Core Replacement HEATER CORE REPLACEMENT TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Use J 38185 in order to position aside the heater hose inlet and outlet clamps at the heater core. 4. Disconnect the inlet and outlet heater hose from the heater core. 5. Remove the RH Instrument Panel Closeout/Insulator panel. 6. Remove the LH Instrument Panel Closeout/Insulator panel 7. Remove the floor carpet. 8. Remove the rear floor air outlet duct from the holes in the floor reinforcement. 9. Disconnect the rear floor air outlet duct from the heater air outlet cover. 10. Remove the rear floor air outlet duct. 11. Remove the heater air outlet cover screws (2). 12. Remove the heater air outlet cover heat stakes (1) with a small chisel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 2620 13. Remove the heater air outlet cover from the HVAC module assembly. 14. Remove the heater core cover screws (2). 15. Remove the heater core cover heat stakes (1) with a small chisel. 16. Remove the heater core cover from the HVAC module assembly. 17. Remove the heater core from the HVAC module assembly. 18. Remove the heater core foam seal (1) from the HVAC module assembly. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 2621 1. Install a new heater core foam seal (1) to the HVAC module assembly. 2. Install the heater core to the HVAC module assembly. 3. From the inside of the heater core cover, drill the dimples adjacent to the heat stakes using a 5.5 mm (7/32 in) drill bit. 4. Install the heater core cover to the HVAC module assembly. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the heater core cover screws (2). Tighten Tighten all screws to 1.5 N.m (13 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 2622 6. From the inside of the heater air outlet cover, drill the dimples adjacent to the heat stakes using a 5.5 mm (7/32 in) drill bit. 7. Install the heater air outlet cover. 8. Install the heater air outlet cover screws (2). Tighten Tighten the screws to 1.5 N.m (13 lb in). 9. Connect the rear floor air outlet duct to the heater air outlet cover. 10. Install the rear floor air outlet duct to the holes in the floor reinforcement. 11. Install the floor carpet. 12. Install the RH Instrument Panel Closeout/Insulator panel. 13. Install the LH Instrument Panel Closeout/Insulator panel. 14. Connect the inlet and outlet heater hose to the heater core. 15. Use J 38185 in order to reposition the heater hose inlet and outlet clamps to the heater core. 16. Install the fuel injector sight shield. 17. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet Heater Hose: Service and Repair Heater Hose Replacement - Inlet HEATER HOSE REPLACEMENT - INLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the fuel injector sight shield. 3. Use J 38185 in order to position aside the heater hose inlet clamp at the pipe adapter. 4. Disconnect the heater inlet hose from the pipe adapter. 5. Use J 38185 in order to position aside the heater core inlet hose clamp. 6. Disconnect the heater inlet hose from the heater core. 7. Remove the heater inlet hose from the support bracket. INSTALLATION PROCEDURE 1. Install the heater inlet hose to the support bracket. 2. Connect the heater inlet hose to the heater core. 3. Use J 38185 in order to secure the heater core hose inlet clamp. 4. Connect the heater inlet hose to the pipe adapter. 5. Use J 38185 in order to secure the heater hose inlet clamp. 6. Install the fuel injector sight shield. 7. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 2627 Heater Hose: Service and Repair Heater Hose Replacement - Outlet HEATER HOSE REPLACEMENT - OUTLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the fuel injector sight shield. 3. Use J 38185 in order to position aside the heater hose outlet clamp at the pipe adapter. 4. Disconnect the heater outlet hose from the pipe adapter. 5. Use J 38185 in order to position aside the heater core outlet hose clamp. 6. Disconnect the heater outlet hose from the heater core. 7. Remove the heater outlet hose from the support bracket. INSTALLATION PROCEDURE 1. Install the heater outlet hose to the support bracket. 2. Connect the heater outlet hose to the heater core. 3. Use J 38185 in order to secure the heater core hose outlet clamp. 4. Connect the heater outlet hose to the pipe adapter. 5. Use J 38185 in order to secure the heater hose outlet clamp. 6. Install the fuel injector sight shield. 7. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 2628 Heater Hose: Service and Repair Heater Pipe Replacement - Inlet HEATER PIPE ADAPTER REPLACEMENT - INLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the fuel injector sight shield. 3. Use J 38185 in order to position aside the heater hose clamp. 4. Disconnect the heater inlet hose from the heater pipe adapter. 5. Remove the heater pipe adapter mounting bolt. 6. Remove the heater pipe adapter. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 2629 1. Lubricate the O-ring seal with Dex-Cool antifreeze. 2. Install the heater pipe adapter. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the heater inlet pipe adapter mounting bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Connect the inlet hose to the heater pipe adapter. 5. Use J 38185 in order to secure the heater core hose clamp. 6. Install the fuel injector sight shield. 7. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 2630 Heater Hose: Service and Repair Heater Pipe Adapter Replacement - Outlet HEATER PIPE ADAPTER REPLACEMENT - OUTLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the fuel injector sight shield. 3. Use J 38185 in order to position aside the heater hose clamp. 4. Remove the heater outlet hose from the heater pipe adapter. 5. Remove the heater pipe adapter mounting bolt. 6. Remove the heater pipe adapter. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 2631 1. Lubricate the O-ring seal with Dex-Cool antifreeze. 2. Install the heater pipe adapter. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the heater outlet pipe adapter mounting bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the heater outlet hose to the pipe adapter. 5. Use J 38185 in order to secure the heater core hose clamp. 6. Install the fuel injector sight shield. 7. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug > Component Information > Service and Repair Radiator Drain Plug: Service and Repair Drain Cock Replacement Removal Procedure 1. Drain the cooling system. 2. Unscrew the radiator drain cock from the radiator. 3. Remove the drain cock from the radiator side tank with a firm tug. 4. Remove the drain cock seal from the drain cock. Installation Procedure 1. Install the seal on the drain cock stem. 2. Install the drain cock. Make sure that the body is fully seated in the side tank of the radiator. 3. Screw the radiator drain cock in to the radiator. 4. Fill the cooling system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Testing and Inspection Radiator Cap: Testing and Inspection Pressure Cap Testing - Tools Required J 24460-01 Cooling System Pressure Tester - J 42401 Radiator Cap/Surge Tank Test Adapter Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot. 1. Remove the pressure cap. 2. Wash the pressure cap sealing surface with water. 3. Use the J 24460-01 (1) with J 42401(2) in order to test the pressure cap. 4. Test the pressure cap for the following conditions: - Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. - Maintain the rated pressure for at least 10 seconds. Note the rate of pressure loss. 5. Replace the pressure cap under the following conditions: - The pressure cap does not release pressure which exceeds the rated pressure of the cap. - The pressure cap does not hold the rated pressure. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet Radiator Hose: Service and Repair Inlet Radiator Hose Replacement - Inlet (3.8L) - Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Partially drain the cooling system. 2. Remove the left diagonal brace. 3. Use the J 38185 in order to reposition the hose clamp from the radiator. 4. Remove the radiator inlet hose from the radiator. 5. Use the J 38185 in order to reposition the hose clamp from the water outlet housing. 6. Remove the radiator inlet hose from the water outlet housing and the vehicle. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet > Page 2643 1. Align the marks on the hose. Install the radiator inlet hose to the water outlet housing. 2. Use the J 38185 in order to reposition and install the hose clamp to the water outlet housing. 3. Install the radiator inlet hose to the radiator. 4. Use the J 38185 in order to reposition and install the hose clamp to the radiator. 5. Install the left diagonal brace. 6. Fill the cooling system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet > Page 2644 Radiator Hose: Service and Repair Outlet Radiator Hose Replacement - Outlet (3.8L) - Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Drain the cooling system. 2. Remove the lower radiator air deflector. 3. Use the J 38185 in order to reposition the hose clamp from the radiator. 4. Remove the radiator outlet hose (3) from the radiator (2). 5. Lower the vehicle. 6. Use J 38185 in order to reposition the hose clamp from the water pump housing. 7. Remove the radiator outlet hose from the water pump housing. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information > Service and Repair > Inlet > Page 2645 1. Align the marks on the hose. Install the radiator outlet hose to the water pump housing. 2. Use J 38185 in order to reposition the hose clamp to the water pump housing. 3. Raise and support the vehicle. 4. Install the radiator outlet hose (3) to the radiator (2). 5. Use J 38185 in order to reposition the hose clamp to the radiator. 6. Install the lower radiator air deflector. 7. Fill the cooling system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2651 Engine Coolant Temperature (ECT) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2652 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Partially drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the thermostat housing. 3. Disconnect the ECT sensor electrical connector. 4. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. 1. Coat the threads with sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2653 3. Connect the ECT sensor electrical connector. 4. Install the thermostat housing. 5. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications Thermostat: Specifications Thermostat Full Open Temperature .................................................................................................... ................................................................ 195 degrees Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2657 Thermostat: Service and Repair Thermostat Replacement (3.8L) - Tools Required J 38185 Hose Clamp Pliers Removal Procedure 1. Remove the fuel injector sight shield. 2. Partially drain the cooling system. 3. Use the J 38185 to reposition the hose clamp from the water outlet housing. 4. Remove the radiator inlet hose from the water outlet housing. 5. Remove the water outlet housing bolt and the stud. 6. Remove the water outlet housing and the gasket. 7. Remove the thermostat. 8. Inspect and clean the water outlet housing mating surfaces. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Specifications > Page 2658 1. Install the thermostat. 2. Install the gasket and the water outlet housing. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the water outlet housing bolt and the stud. - Tighten the bolt and the stud to 27 Nm (20 ft. lbs.). 4. Install the radiator inlet hose to the water outlet housing. 5. Use the J 38185 to reposition install the hose clamp to the water outlet housing. 6. Fill the cooling system. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications Water Pump: Specifications Water Pump Bolt Large Bolt ............................................................................................................................................ ................................................. 34 Nm (25 ft. lbs.) Small Bolt ............................................................. .......................................................................................................................... 13 Nm (116 inch lbs.) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2662 Water Pump: Service and Repair Water Pump Replacement (3.8L) Removal Procedure 1. Drain the cooling system. 2. Loosen the water pump pulley bolts. 3. Remove the drive belt. 4. Remove the water pump pulley bolts. 5. Remove the water pump pulley. 6. Remove the power steering pump and reposition. 7. Remove the water pump bolts. 8. Remove the water pump. 9. Remove the water pump gasket. 10. Clean and inspect the water pump mating surfaces. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Specifications > Page 2663 1. Install the water pump gasket. 2. Install the water pump. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the water pump bolts. - Tighten the long water pump bolts to 34 Nm (25 ft. lbs.). - Tighten the short water pump bolts to 22 Nm (16 ft. lbs.). 4. Install the water pump pulley. 5. Install the water pump pulley bolts. - Tighten the bolts to 13 Nm (115 inch lbs.). 6. Install the power steering pump. 7. Install the drive belt. 8. Fill the cooling system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Actuators and Solenoids - Exhaust System > Catalytic Converter Bypass Valve Actuator > Component Information > Service and Repair Catalytic Converter Bypass Valve Actuator: Service and Repair BYPASS VALVE ACTUATOR REPLACEMENT TOOLS REQUIRED J 39363 Supercharger Actuator Adjuster REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Remove the boost control solenoid. 3. Remove the vacuum hoses from the bypass actuator. 4. Remove the bypass valve actuator mounting bolts and rotate the bypass valve actuator until the rod disengages the lever. INSTALLATION PROCEDURE 1. Install the J 39363 to the actuator. IMPORTANT: When installing the bypass valve actuator to the supercharger, rotate the assembly until the bypass valve shaft lever comes in contact with the stop block. 2. Rotate the actuator until the rod engages the lever. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bypass valve actuator bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Actuators and Solenoids - Exhaust System > Catalytic Converter Bypass Valve Actuator > Component Information > Service and Repair > Page 2669 4. Remove the J 39363. 5. Install the vacuum hoses to the bypass actuator. 6. Install the boost control solenoid. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalytic Converter Bypass Valve Actuator > Component Information > Service and Repair Catalytic Converter Bypass Valve Actuator: Service and Repair BYPASS VALVE ACTUATOR REPLACEMENT TOOLS REQUIRED J 39363 Supercharger Actuator Adjuster REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Remove the boost control solenoid. 3. Remove the vacuum hoses from the bypass actuator. 4. Remove the bypass valve actuator mounting bolts and rotate the bypass valve actuator until the rod disengages the lever. INSTALLATION PROCEDURE 1. Install the J 39363 to the actuator. IMPORTANT: When installing the bypass valve actuator to the supercharger, rotate the assembly until the bypass valve shaft lever comes in contact with the stop block. 2. Rotate the actuator until the rod engages the lever. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bypass valve actuator bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Catalytic Converter Bypass Valve Actuator > Component Information > Service and Repair > Page 2674 4. Remove the J 39363. 5. Install the vacuum hoses to the bypass actuator. 6. Install the boost control solenoid. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair Exhaust Crossover Pipe: Service and Repair Exhaust Crossover Pipe Replacement (3.8L) Removal Procedure 1. Remove the fuel injector sight shield. 2. Remove the air cleaner intake duct. 3. Remove the exhaust crossover heat shield nuts. 4. Remove the exhaust crossover heat shield. 5. Remove the exhaust crossover pipe bolts. 6. Remove the exhaust crossover pipe. 7. Remove the exhaust crossover pipe seal. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component Information > Service and Repair > Page 2678 1. Install the exhaust crossover pipe seal to the exhaust crossover pipe at the right exhaust manifold connection. 2. Install the exhaust crossover pipe. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the exhaust crossover pipe bolts. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 4. Install the exhaust crossover heat shield. 5. Install the exhaust crossover heat shield nuts. ^ Tighten the nuts to 20 Nm (15 ft. lbs.). 6. Install the air cleaner intake duct. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Left Exhaust Manifold Replacement - Left (3.8L) Removal Procedure 1. Remove the fuel injector sight shield. 2. Remove the right and the left engine mount struts. 3. Remove the lower right engine mount strut bracket. 4. Remove the exhaust crossover pipe from the left exhaust manifold. 5. Remove the spark plug wires from the left side spark plugs. 6. Remove the oil level indicator tube. 7. Remove the left engine lift bracket nut, bolt and engine lift bracket. 8. Remove the left exhaust manifold heat shield nuts and the exhaust manifold heat shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2683 9. Remove the left exhaust manifold bolts and the studs. 10. Remove the left exhaust manifold and the gasket. 11. Clean and inspect the left exhaust manifold mating surfaces. Installation Procedure 1. Install the left exhaust manifold gasket and the left exhaust manifold to the cylinder head. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the left exhaust manifold bolts and the studs to the left exhaust manifold. ^ Tighten the bolts and the studs to 30 Nm (22 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2684 3. Install the left exhaust manifold heat shield to the exhaust manifold. 4. Install the exhaust manifold heat shield nuts. ^ Tighten the nuts to 20 Nm (15 ft. lbs.). 5. Install the left engine lift bracket. 6. Install the engine lift bracket nut and the bolt. ^ Tighten the nut and the bolt to 30 Nm (22 ft. lbs.). 7. Install the oil level indicator tube. 8. Install the spark plug wires to the left side spark plugs. 9. Install the exhaust crossover to the left exhaust manifold. 10. Install the lower right engine mount strut bracket. 11. Install the right and the left engine mount struts. 12. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2685 Exhaust Manifold: Service and Repair Exhaust Manifold Replacement - Right Exhaust Manifold Replacement Right (3.8L) Removal Procedure 1. Remove the cross vehicle brace. 2. Remove the fuel injector sight shield. 3. Remove the exhaust crossover heat shield nuts. 4. Remove the exhaust crossover heat shield. 5. Remove the exhaust crossover pipe bolts from the right exhaust manifold. 6. Raise and support the vehicle. Refer to Vehicle Lifting. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2686 7. Remove the exhaust manifold pipe stud nuts and the catalytic converter pipe from the right exhaust manifold. 8. Remove the Exhaust Gas Recirculation (EGR) valve inlet adapter pipe bolt from the right exhaust manifold. 9. Lower the vehicle. 10. Rotate the engine to access the right side of the engine. 11. Disconnect the Heated Oxygen (HO2S) Sensor electrical connector (4). 12. Remove the Heated Oxygen (HO2S) Sensor electrical connector (4) from the engine sight shield bracket (1). 13. Remove the right side spark plugs from cylinders 2, 4 and 6. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2687 14. Remove the right engine lift bracket bolt and the nut. 15. Remove the right engine lift bracket. 16. Remove the fuel injector sight shield bracket nuts. 17. Remove the fuel injector sight shield bracket. 18. Remove the right exhaust manifold bolts and the nuts. 19. Remove the right exhaust manifold. 20. Remove the right exhaust manifold gasket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2688 21. Remove the upper right exhaust manifold heat shield. 22. Remove the lower right exhaust manifold heat shield. 23. If replacing the right exhaust manifold remove the Heated Oxygen Sensor (HO2S) from the right exhaust manifold. 24. Remove the exhaust manifold studs if damaged. 25. Clean and Inspect the right exhaust manifold. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2689 1. Install the exhaust manifold studs if removed. 2. If replacing the right exhaust manifold, install the Heated Oxygen Sensor (HO2S) to the right exhaust manifold. 3. Install the lower right exhaust manifold heat shield. 4. Install the upper right exhaust manifold heat shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2690 5. Install the new right exhaust manifold gasket. 6. Install the right exhaust manifold. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the right exhaust manifold bolts and the nuts. ^ Tighten the bolts and the nuts to 30 Nm (22 ft. lbs.). 8. Install the fuel injector sight shield bracket. 9. Install the fuel injector sight shield bracket nuts. ^ Tighten the nuts to 30 Nm (22 ft. lbs.). 10. Install the right engine lift bracket. 11. Install the right engine lift bracket bolt and the nut. ^ Tighten the bolt and the nut to 30 Nm (22 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2691 12. Install the right side spark plugs to cylinders 2, 4 and 6. 13. Install the Heated Oxygen Sensor (HO2S) electrical connector (4) to the engine sight shield bracket (1). 14. Connect the Heated Oxygen Sensor (HO2S) electrical connector (4). 15. Return the engine to the original position. 16. Raise the vehicle. 17. Install the EGR valve inlet adapter pipe to the right exhaust manifold. ^ Tighten the bolt to 29 Nm (21 ft. lbs.). 18. Install the catalytic converter pipe to the right exhaust manifold. 19. Install the catalytic converter pipe stud nuts to the right exhaust manifold. ^ Tighten the stud nuts to 32 Nm (24 ft. lbs.). 20. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information > Service and Repair > Exhaust Manifold Replacement - Left > Page 2692 21. Install the exhaust crossover bolts to the right exhaust manifold. ^ Tighten the bolts to 20 Nm (15 ft. lbs.). 22. Install the exhaust crossover heat shield. 23. Install the exhaust crossover heat shield nuts. ^ Tighten the nuts to 20 Nm (15 ft. lbs.). 24. Install the engine mount struts. 25. Install the fuel injector sight shield. 26. Install the cross vehicle brace. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Hanger Exhaust Pipe/Muffler Hanger: Service and Repair Hanger Exhaust Hanger Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the exhaust system. 3. Remove the exhaust pipe hanger (3) from the exhaust pipe (2) and the exhaust hanger bracket (1). 4. Remove the exhaust pipe hanger from the exhaust pipe and the exhaust hanger bracket. 5. Remove the exhaust pipe rear hangers from the muffler and the rear exhaust hanger brackets. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Hanger > Page 2697 Installation Procedure 1. Install the exhaust pipe rear hangers to the muffler and the rear exhaust hanger brackets. 2. Install the exhaust pipe hanger to the exhaust pipe and the exhaust hanger bracket. 3. Install the exhaust pipe hanger (3) to the exhaust pipe (2) and the exhaust hanger bracket (1). 4. Remove the support from the exhaust system. 5. Inspect the exhaust system for underbody contact. 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Hanger > Page 2698 Exhaust Pipe/Muffler Hanger: Service and Repair Hanger Bracket Exhaust Hanger Mounting Bracket Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. Notice: Refer to Catalytic Converter Movement Notice in Service Precautions. 2. Support the exhaust system. 3. Remove the exhaust pipe rear hanger insulators from the exhaust muffler rear hanger bracket. 4. Loosen the outboard rear bumper impact bar bolt. 5. Remove the inboard rear bumper impact bar bolt. 6. Remove the exhaust muffler rear hanger bracket. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Hanger > Page 2699 1. Install the exhaust muffler rear hanger bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the inboard and the outboard rear bumper impact bar bolts. ^ Tighten the bolts to 25 Nm (18 ft. lbs.). 3. Install the exhaust pipe rear hanger insulators to the exhaust muffler rear hanger bracket. 4. Remove the support from the exhaust system. 5. Inspect the exhaust system for underbody contact. 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component Information > Service and Repair > Hanger > Page 2700 Exhaust Pipe/Muffler Hanger: Service and Repair Converter Hanger Assembly Converter Hanger Assembly Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. Notice: Refer to Catalytic Converter Movement Notice in Service Precautions. 2. Support the exhaust system 3. Remove the 3-way catalytic converter pipe hangers. 4. Inspect the 3-way catalytic converter brackets for serviceability. Repair or replace as necessary. Installation Procedure 1. Install the 3-way catalytic converter pipe hangers. 2. Remove the support from the exhaust system and the vehicle. 3. Inspect the exhaust system for underbody contact. 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Dual Muffler: Service and Repair Dual Muffler Replacement (Dual) Removal Procedure Important: The muffler is serviced as a complete assembly and cannot be serviced separately. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the exhaust system. 3. Remove the catalytic converter from the muffler. 4. Remove the muffler from the exhaust hangers. 5. Clean the catalytic converter and the muffler gasket mating surfaces. Installation Procedure 1. Install the muffler to the exhaust hangers. 2. Support the exhaust system. 3. Install a new gasket to the catalytic converter and the muffler. 4. Install the catalytic converter to the muffler. 5. Remove the exhaust system support. 6. Lower the vehicle. 7. Inspect for exhaust leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Dual > Page 2705 Muffler: Service and Repair Single Muffler Replacement (Single) Removal Procedure Important: The muffler is serviced as a complete assembly and cannot be serviced separately. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Support the exhaust system. 3. Remove the catalytic converter nuts. 4. Remove the exhaust system from the exhaust hangers. 5. Clean the catalytic converter and the muffler gasket mating surfaces. Installation Procedure 1. Install the muffler to the exhaust hangers. 2. Support the exhaust system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Service and Repair > Dual > Page 2706 3. Install a new gasket to the catalytic converter and the muffler. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the catalytic converter nuts. ^ Tighten the nuts to 60 Nm (44 ft. lbs.). 5. Remove the exhaust system support. 6. Lower the vehicle. 7. Inspect for exhaust leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair Exhaust Pipe Gasket: Service and Repair Exhaust Seal Replacement (3.8L) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. Notice: Refer to Catalytic Converter Movement Notice in Service Precautions. Important: Use caution handling the pipe that contains an oxygen sensor. Do not cut the wire. For removal or repositioning disconnect the H02S electrical connector. 2. Remove the exhaust manifold nuts from the exhaust manifold pipe studs. Important: Support the exhaust system where hangers are removed. 3. Remove the catalytic converter exhaust hangers. 4. Reposition the exhaust system. 5. Remove the exhaust manifold pipe gasket. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Seals and Gaskets, Exhaust > Exhaust Pipe Gasket > Component Information > Service and Repair > Page 2711 1. Install the exhaust manifold pipe gasket. 2. Install the exhaust system to the original position. 3. Install the catalytic converter exhaust hangers. 4. Remove the support from the exhaust system. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the exhaust manifold pipe nuts to the exhaust manifold pipe studs. ^ Tighten the nuts to 35 Nm (26 ft. lbs.). 6. Inspect the exhaust system for leaks and underbody contact. 7. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: Customer Interest BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 2723 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: All Technical Service Bulletins BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 2729 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 2739 Behind Left Side Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 Body Control Module: Diagrams Body Control Module (BCM) C1 Body Control Module, C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2742 Body Control Module, C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2743 Body Control Module, C1 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2744 Body Control Module: Diagrams Body Control Module (BCM) C2 Body Control Module, C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2745 Body Control Module, C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2746 Body Control Module: Diagrams Body Control Module (BCM) C3 Body Control Module, C3 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 2747 Body Control Module, C3 Part 2 Body Control Module, C3 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 2748 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. The BCM has five basic modes (disarmed, standby, delayed, armed, and alarm) for operating the CTD system. The different modes are described below. 1. The BCM has the CTD system in a disarmed mode until the following conditions are detected: - Ignition key turned to the OFF position. - Any door open. - Doors locked by either the power door lock switch or the LOCK button on the transmitter. 2. The BCM enters the standby mode when the above conditions are detected. In standby mode, the BCM commands the SECURITY indicator to flash. If all the doors are closed and the LOCK button on the transmitter is used, the BCM enters the delayed mode. 3. When the last door is closed, the BCM enters the delayed mode for 30 seconds. In delayed mode the BCM commands the SECURITY indicator to illuminate ON steady. 4. After 30 seconds, the BCM enters the armed mode. Any forced entry activates the alarm mode. 5. When the BCM detects a forced entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active.The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. The body control module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(TM) data from the Passlock(TM) sensor. If the Passlock(TM) data is correct, the BCM will send a class 2 message to the PCM to enable the fuel injectors and crank relay. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(TM) data, the VTD system will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors and crank relay for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(TM) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable and crank relay enable signal to the PCM. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION During body control module (BCM) related service, the procedures below are designated to set-up the BCM correctly. Before you start, read these procedures carefully and completely. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: The BCM will not function properly if the Setup New BCM procedure is not performed. - Make sure the battery is fully charged before performing the setup procedure. - Make sure all disconnected devices and connectors have been reconnected - Perform the Theft Deterrent Re-learn procedure after successfully finishing the Setup New BCM procedure. Refer to Programming Theft Deterrent System Components in Theft Deterrent. If the Theft Deterrent Re-learn procedure is not performed after a BCM replacement, the following conditions may occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. 1. Connect a scan tool to the data link connector (DLC). 2. Turn the ignition switch ON. 3. Select Diagnostics and input all of the required data when prompted by the scan tool. 4. Select BODY CONTROL MODULE. 5. Select SPECIAL FUNCTIONS. 6. Select New VIN and input all required data. 7. Exit back to the SPECIAL FUNCTIONS menu. 8. Select BCM REPROGRAMMING. 9. The scan tool will display DO YOU WANT TO SETUP A BODY CONTROL MODULE? At the prompt, select SETUP BCM hotspot on the scan tool. 10. The scan tool will display: NOW SETTING UP THE NEW BODY CONTROL MODULE. 11. When the BCM has been setup successfully, the scan tool will display: BODY CONTROL MODULE SETUP IS COMPLETE. 12. Exit back to the SPECIAL FUNCTIONS menu. 13. Select Point of Sale in this menu. 14. Input all of the required data when prompted by the scan tool. 15. Exit back to the SET OPTIONS menu. 16. Select Option Configuration. 17. Input all of the required data when prompted by the scan tool. 18. When the BCM, VIN, Point of Sale and Option Configuration have been entered, proceed with the Theft Deterrent Re-learn procedure. 19. If the scan tool displays UNABLE TO PROGRAM BCM. BCM IS SECURED, then the BCM must be replaced and this procedure must be repeated on a new BCM. NOTE: After the above procedure has been completed, personalization of the BCM defaults to a default setting. Inform the customer that the personalization settings must be set again. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 2751 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: You must perform the new body control module (BCM) setup when replacing the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 1. Disconnect the battery ground (negative) cable. 2. Remove the left instrument panel insulator. 3. Disconnect the BCM electrical connectors (2,3,4). 4. Remove the BCM (1). INSTALLATION PROCEDURE 1. Install the body control module (BCM) (1). 2. Connect the BCM electrical connectors (2,3,4). 3. Install the left instrument panel insulator. 4. Connect the battery ground (negative) cable. 5. Perform the new BCM setup. Refer to Body Control Module (BCM) Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 2756 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2757 Left Front Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 Engine Control Module: Diagrams Powertrain Control Module, C1 Powertrain Control Module, C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 2760 Powertrain Control Module, C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 2761 Powertrain Control Module, C1 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 2762 Powertrain Control Module, C1 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 2763 Engine Control Module: Diagrams Powertrain Control Module, C2 Powertrain Control Module, C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 2764 Powertrain Control Module, C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 2765 Powertrain Control Module, C2 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 2766 Powertrain Control Module, C2 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module Engine Control Module: Description and Operation Powertrain Control Module POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION The PCM communicates with the BCM over the Class 2 serial data line. When the BCM determines an incorrect password, it sends a Class 2 serial data password to the PCM in order to disable the crank relay and fuel injection system. If the BCM receives the expected voltage from the Passlock(TM) sensor, the BCM sends a class 2 serial data password to the PCM in order to enable the crank relay and fuel injection system. The PCM then allows the vehicle to start normally. POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module > Page 2769 The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the PCM, allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e. misfire). WARM-UP CYCLE The PCM uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160 °F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The PCM is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module > Page 2770 Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the MIL or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. The last test may have run during a previous ignition cycle if an A or B type DTC is displayed. For type C DTCs, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MIL Request: Indicates that this DTC is currently requesting the MIL. This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History: Indicates that the DTC is stored in the PCM History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear): DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module > Page 2771 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM maintains proper spark and fuel injection timing for all driving conditions. Ignition control (IC) spark timing is the method the PCM uses to control spark advance. To provide optimum driveability and emissions, the PCM monitors input signals from the following components to calculate ignition spark timing: The ignition control module (ICM) - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) The following describes the PCM to ICM circuits: Low resolution engine speed signal-3 X reference-PCM input-from the ICM. The 3X reference signal is produced by the ICM. The PCM uses this signal to calculate engine RPM and crankshaft position above 1,200 RPM. The PCM also uses the pulses on this circuit to initiate fuel injector operation. The PCM compares the number of 3X pulses to the number of 18X and cam pulses. If the number of 3X pulses are incorrect while the engine is cranking or running, the PCM will set a DTC. The engine will continue to start and run normally using the 18X reference signal. - Medium resolution engine speed signal-18 X reference-PCM input-from the ICM. The 18 X reference signal is used to accurately control spark timing at low RPM and allow ignition control (IC) operation during cranking. The ICM calculates the 18X reference signal by filtering the CKP sensor 18X pulses when the engine is running and the CKP sync pulses are being received. Below 1,200 RPM, the PCM is monitoring the 18X reference signal and using the 18X signal as the reference for ignition timing advance. The PCM compares the number of 18X pulses to the number of 3X and cam pulses. If the number of 18X pulses are incorrect while the engine is cranking or running, the PCM will set a DTC. The engine will continue to start and run normally using the 3X reference signal. - Camshaft position-PCM input-from the ICM. The PCM uses this signal to determine the position of the cylinder #1 piston during the pistons power stroke. This signal is used by the PCM to calculate true sequential fuel injection (SFI) mode of operation. The PCM compares the number of CAM pulses to the number of 18 X and 3 X reference pulses. If the number of 18 X and 3 X reference pulses occurring between CAM pulses is incorrect, or if no CAM pulses are received while the engine is running, the PCM will set a DTC. If the CAM signal is lost while the engine is running the fuel injection system will shift to a calculated sequential fuel injection mode based on the last CAM pulse, and the engine will continue to run. The engine can be re-started and will run in the calculated sequential mode as long as the condition is present with a 1 in 6 chance of being correct. - Low reference-PCM input-this is a ground circuit for the digital RPM counter inside the PCM, but the wire is connected to engine ground only through the ICM. This circuit assures there is no ground drop between the PCM and ICM. - IC timing signal-PCM output-to the ICM. The ICM controls spark timing while the engine is cranking, this is called bypass mode. Once the PCM receives 3 X reference signals from the ICM, the PCM applies 5 volts to the IC timing signal circuit allowing the ICM to switch spark advance to PCM control. - IC timing control-PCM output-to the ICM. The IC output circuitry of the PCM sends out timing signals to the ICM on this circuit. When in the Bypass Mode, the ICM grounds these signals. When in the IC Mode, the signals are sent to the ICM to control spark timing. - Default mode due to a system failure The other mode is the IC mode during which the PCM is receiving the 18X and the 3X reference pulses from the CKP sensor and is supplying 5 volts to the IC timing signal circuit. This allow the PCM to accurately control spark timing for all driving conditions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2772 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for PCM replacement, inspect the PCM first to see if the replacement is the correct part. If the PCM is faulty, remove the PCM and install the new service PCM. The new service PCM will not be programmed. You must program the new PCM. DTC P0602 indicates the EEPROM is not programmed or has malfunctioned. NOTE: - Do not touch the connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage to the PCM. - Turn the ignition OFF when installing or removing the PCM connectors and disconnecting or reconnecting the power to the PCM (battery cable, PCM pigtail, PCM fuse, jumper cables, etc.) in order to prevent internal PCM damage. Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the left front inner fender brace. 3. Remove the air cleaner intake duct. 4. Remove the air cleaner housing cover screws (2). 5. Remove the air cleaner housing cover (1). 6. Without disconnecting the PCM electrical connectors, remove the PCM and the wiring harness from the air cleaner housing assembly (3). 7. Disconnect the PCM electrical connectors and remove the PCM. Installation Procedure NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the PCM to the PCM electrical connectors. Tighten Tighten the connectors to 8 N.m (71 lb in). 2. Install the PCM and the wiring harness to the air cleaner housing assembly (3). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2773 3. Install the air cleaner housing cover (1). 4. Install the air cleaner housing cover screws (2). Tighten Tighten the screws to 4 N.m (35 lb in). 5. Install the air cleaner intake duct. 6. Install the left front inner fender brace. 7. Connect the negative battery cable. 8. The new PCM must be programmed. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2778 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2779 Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2780 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2781 Right Side Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2782 Ignition Control Module: Diagrams Ignition Control Module (ICM) Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2783 Ignition Control Module (ICM) Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2784 Ignition Control Module: Description and Operation IGNITION CONTROL MODULE (ICM) AND IGNITION COILS Three dual tower ignition coils are mounted to the ICM, and are serviced individually. The ICM performs the following functions: - The ICM supplies a power and low reference circuit to the CMP and CKP sensors. - The ICM determines the correct direction of the crankshaft rotation, and cuts spark and fuel delivery to prevent damage from backfiring if reverse rotation is detected. - The ICM determines the correct coil triggering sequence, based on how many 18 X ON-OFF pulses occur during a sync pulse. This coil sequencing occurs at start-up, and is remembered by the ICM. After the engine is running, the ICM will continue to trigger the coils without the CKP sync pulse. - The ICM inputs 18 X and 3 X reference signals to the PCM. - The 3 X reference signal is also known as the low resolution engine speed signal. This signal is generated by the ICM using an internal divide-by-six circuit. This circuit divides the 18 X signal pulses by 6. This divider circuit will not begin operation without a sync pulse present at start-up, and without 18 X and 3 X reference signals no fuel injection will occur. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2785 Ignition Control Module: Service and Repair IGNITION CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the 14-way electrical connector from the ignition control module (ICM). 3. Disconnect the spark plug wires from the coil assemblies. Before removing the wires, note the position of the wires. 4. Remove the ignition coil screws (1). 5. Remove the ignition coils (2) from the ICM (3). 6. Remove the ignition control module (3) from the bracket. INSTALLATION PROCEDURE 1. Install the ignition control module to the bracket. 2. Install the ignition coils (2) to the ignition control module (3). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the ignition coil screws (1). Tighten Tighten the screws to 4.5 N.m (40 lb in). 4. Connect the spark plug wires. 5. Connect the 14-way electrical connector to the module. Tighten Tighten the screw to 2.1 N.m (19 lb in). 6. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The ignition relay is a normally open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the run or start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by the relay coil, overcomes the spring tension and moves the armature allowing the relay contact to close. The closed relay contacts allow current to flow from the battery to the following fuses: Eng Devices - Oxy Sensors - DFI/MDL - Trans Sol - A/C Relay fuse - Fuel Inj When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the ignition relay fails to close, the engine will crank, but will not run. The class 2 communications will be available with the use of a scan tool. The ignition relay table assumes that the vehicle battery is fully charged. Refer to Battery Inspection/Test in Starting and Charging. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test TEST Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 2789 Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 2790 Steps 4-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 2791 Step 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 2792 Steps 7-9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 2793 Steps 10-13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 2794 Steps 14-16 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 2795 Steps 17-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 2796 Steps 21-22 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 2797 Steps 23-25 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 2798 Steps 26-34 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations Left Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2804 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2805 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2806 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2807 Mass Air Flow (MAF) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2808 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. IMPORTANT: The mass air flow (MAF) sensor is attached to the throttle body assembly. 2. Disconnect the MAF sensor electrical connector (8). 3. Remove the MAF sensor screws (9). 4. Remove the MAF sensor (1). INSTALLATION PROCEDURE 1. Install the MAF sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF sensor screws (9). Tighten Tighten the screws to 3 N.m (27 lb in). 3. Connect the MAF sensor electrical connector (8). 4. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2812 Right Middle Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2813 Camshaft Position (CMP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2814 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The camshaft position (CMP) sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor does not directly affect the operation of the ignition system. The CMP sensor information is used by the powertrain control module (PCM) to determine the position of the valve train relative to the CKP. By monitoring the CMP and CKP signals the PCM can accurately time the operation of the fuel injectors. The CMP sensor shares 12-volt and low reference circuits with the CKP sensor. The CMP signal circuit is input to the ICM. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2815 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the coolant recovery reservoir. 2. Remove the drive belt. 3. Disconnect the electrical connector (2) from the camshaft position sensor (1). 4. Remove the camshaft position sensor bolt. 5. Remove the camshaft position sensor from the engine front cover. INSTALLATION PROCEDURE 1. Install the camshaft position sensor to the engine front cover. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 2816 2. Install the camshaft position sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 3. Connect the electrical connector (2) to the camshaft position sensor (1). 4. Install the drive belt. 5. Install the coolant recovery reservoir. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2820 Engine Coolant Temperature (ECT) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2821 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Partially drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the thermostat housing. 3. Disconnect the ECT sensor electrical connector. 4. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. 1. Coat the threads with sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 2822 3. Connect the ECT sensor electrical connector. 4. Install the thermostat housing. 5. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2826 Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2827 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2828 Camshaft Position (CKP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2829 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSORS The crankshaft position (CKP) sensor has a 4-wire harness connector that plugs into the CKP sensor and connects to the ignition control module (ICM). The CKP sensor contains 2 hall-effect switches in 1 housing, and shares a magnet between the switches. The magnet and each hall-effect switch are separated by an air gap. A hall-effect switch is a solid state switching device that produces a digital ON/OFF pulse when a rotating element passes the sensor pick-up and interrupts the magnetic field of the sensor. The rotating element is called an interrupter ring or blade. There are two interrupter rings built into the crankshaft balancer. The outer ring and the outer switch provide the ICM with 18X signals or 18 identical pulses per crankshaft revolution. The inner ring and the inner switch provide the ICM with 3 pulses per revolution, each 1 of different duration. This is called the sync pulse. Each sync pulse represents a pair of companion cylinders. The ICM supplies a 12-volt and a low reference circuit to the CKP sensor, which is also shared by the camshaft position (CMP) sensor. The 18X reference pulses are passed from the CKP sensor to the ICM on the CKP sensor 1 signal circuit. The sync pulses are passed from the CKP sensor to the ICM on the CKP sensor 2 signal circuit. The ICM uses the 18X and sync pulses to determine the crankshaft position by counting how many ON-OFF 18X pulses occur during a sync pulse. With this dual interrupter ring arrangement the ICM can identify the correct pair of cylinders to fire within as little as 120 degrees of crankshaft rotation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2830 Crankshaft Position Sensor: Testing and Inspection CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The ignition control module (ICM) monitors the crankshaft position (CKP) sensor sync signal when the engine is cranking. The CKP sync signal is passed from the CKP sensor to the ICM on the CKP sensor 2 signal circuit. The CKP sync signal is used to determine the correct cylinder pair and initiate the ignition coil firing sequence. The 18X reference pulses are passed from the CKP sensor to the ICM on the CKP sensor 1 signal circuit. The 18X reference pulses are used for fuel injection and ignition control. After the ICM receives both signals, the ICM passes the 18X and 3X reference signals to the powertrain control module (PCM). The camshaft position sensor and the CKP sensor share a 12-volt reference and a low reference circuit. The CKP sensor consists of the following circuits: A 12-volt reference circuit - A low reference circuit - A CKP sensor 1 signal circuit - A CKP sensor 2 signal circuit TEST Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2831 Steps 4-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2832 Steps 8-14 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2833 Steps 15-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2834 Steps 21-26 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2835 Steps 27-28 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 2836 Steps 29-31 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 4.1. Accelerate to wide open throttle (WOT). 4.2. Release throttle when fuel cut-off occurs. 4.3. Observe fuel cut-off specification for applicable engine. 4.4. Engine should not accelerate beyond calibrated RPM value. 4.5. Release throttle immediately if value is exceeded. 4.6. Block drive wheels. 4.7. Set parking brake. 4.8. DO NOT apply brake pedal. 4.9. Cycle ignition from OFF to ON. 4.10. Apply and hold brake pedal. 4.11. Start and idle engine. 4.12. Turn A/C OFF. 4.13. Vehicle must remain in Park or Neutral. 4.14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure.The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - Crankshaft position (CKP) sensors activity - If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity - If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool and perform the following: IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 5.1. Accelerate to WOT. 5.2. Release when fuel cut-off occurs. 5.3. Test in progress. 6. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 . If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC. 7. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set Engine replacement - PCM replacement - A harmonic balancer replacement - Crankshaft replacement - CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2839 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the right splash shield cover. 4. Remove the crankshaft balancer. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the CKP sensor shield (1). 7. Remove the CKP sensor bolts. 8. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 2840 1. Position the CKP sensor to the block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolts. Tighten Tighten the bolts to 30 N.m (22 lb ft) 3. Install the CKP sensor shield (1). 4. Connect the CKP sensor electrical connector. 5. Install the crankshaft balancer. 6. Install the right splash shield cover. 7. Lower the vehicle. 8. Connect the negative battery cable. 9. Perform the Crankshaft Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Fuel Pump And Sender Assembly Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2844 Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 2845 Fuel Level Sensor: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Remove the fuel sender assembly. 2. Disconnect the fuel level sensor electrical connector. 3. Remove the fuel level sensor (5) from the fuel sender assembly. INSTALLATION PROCEDURE 1. Install the fuel level sensor (5) to the fuel sender assembly. 2. Connect the fuel level sensor electrical connector. 3. Install the fuel sender assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations Fuel Pump And Sender Assembly Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2849 Fuel Tank Pressure (FTP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2850 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 2851 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank pressure sensor (7) from the fuel sender assembly (1). 2. Disconnect the negative battery cable. 3. Remove the fuel sender assembly. INSTALLATION PROCEDURE 1. Install the new fuel tank pressure sensor (7) to the fuel sender assembly (1). 2. Install the fuel sender assembly. 3. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Intake Air Temperature (IAT) Sensor: Locations Intake Air Temperature Sensor (IAT) is in the air induction tube. 3. Intake Air Temperature (IAT) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature (IAT) Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2857 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2858 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2859 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2860 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2861 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2862 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2863 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2864 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2865 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2866 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2867 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2868 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2869 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2870 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2871 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2872 Intake Air Temperature (IAT) Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2873 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2874 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2875 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2876 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2877 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2878 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2879 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2880 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2881 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2882 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2883 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2884 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2885 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2886 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2887 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2888 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2889 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2890 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2891 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2892 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2893 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2894 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2895 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2896 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2897 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2898 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2899 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 2900 Intake Air Temperature (IAT) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 2901 Intake Air Temperature (IAT) Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector. 2. Remove the IAT sensor (3) with a twisting and pulling motion. INSTALLATION PROCEDURE 1. Install the IAT sensor (3). 2. Connect the IAT sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Lower Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2905 Rear Middle Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2906 Knock Sensor: Diagrams Knock Sensor (KS) 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2907 Knock Sensor (KS) 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2908 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This KS system uses one or two broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement Knock Sensor: Service and Repair Knock Sensor (KS) 1 Replacement KNOCK SENSOR (KS) 1 REPLACEMENT REMOVAL PROCEDURE CAUTION: Hot engine coolant may cause severe burns. Although the cooling system has been drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of the knock sensor. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Disconnect the knock sensor electrical connector (2). 4. Remove the knock sensor (1). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. 1. Install the knock sensor (1). Tighten Tighten the knock sensor to 19 N.m (14 lb ft). 2. Connect the knock sensor electrical connector (2). 3. Lower the vehicle. 4. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement > Page 2911 Knock Sensor: Service and Repair Knock Sensor (KS) 2 Replacement KNOCK SENSOR (KS) 2 REPLACEMENT REMOVAL PROCEDURE CAUTION: Hot engine coolant may cause severe burns. Although the cooling system has been drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of the knock sensor. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Remove the bolts (2) from the knock sensor heat shield (1). 4. Disconnect the knock sensor electrical connector (3) from the knock sensor. 5. Remove the knock sensor (4). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. 1. Install the knock sensor (4). Tighten Tighten the knock sensor to 19 N.m (14 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement > Page 2912 2. Install the knock sensor heat shield. Tighten Tighten the bolts to 60 N.m (44 lb ft). 3. Connect the knock sensor electrical connector. 4. Lower the vehicle. 5. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2916 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2917 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2918 Manifold Absolute Pressure (MAP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2919 Manifold Pressure/Vacuum Sensor: Testing and Inspection MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR DIAGNOSIS CIRCUIT DESCRIPTION VIN K The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure which gives an indication of the engine load. The MAP sensor has a 5-volt reference circuit, a low reference circuit, and a signal circuit. The powertrain control module (PCM) supplies 5 volts to the MAP sensor on the 5-volt reference circuit and provides a ground on the low reference circuit. The MAP sensor provides a signal to the PCM on the MAP sensor signal circuit, which is relative to the pressure changes in the manifold. With low MAP, such as during idle or deceleration, the PCM should detect a low MAP sensor signal voltage. With high MAP, such as ignition ON, engine OFF, or wide open throttle (WOT), the PCM should detect a high MAP sensor signal voltage. This MAP sensor will indicate pressure between 10-104 kPa. The MAP sensor is also used in order to calculate the barometric pressure (BARO) when the ignition switch is turned ON, with the engine OFF. The BARO reading may also be updated whenever the engine is operated at WOT. The PCM monitors the MAP sensor signal for voltage outside of the normal range. If the PCM detects a MAP sensor signal voltage that is excessively low, DTC P0107 sets. If the PCM detects a MAP sensor signal voltage that is excessively high, DTC P0108 sets. TEST DESCRIPTION Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2920 Steps 4-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2921 Steps 6-10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2922 Steps 11-14 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2923 Steps 15-16 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2924 Steps 17-22 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2925 Steps 23-29 The number below refers to the step number on the diagnostic table. 4. This step tests the MAP sensor's ability to correctly indicate BARO. 12. The measurement noted in this step will be used in subsequent steps if the measurement does not exceed the specified value. 15. This step calculates the resistance in the 5-volt reference circuit. 16. This step calculates the resistance in the low reference circuit. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 2926 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT On the L36, the manifold absolute pressure (MAP) sensor is mounted to the positive crankcase ventilation (PCV) valve cover. Removal Procedure 1. Remove the fuel injector sight shield. 2. Disconnect the MAP sensor electrical connector. 3. Carefully release the locking tabs holding the MAP (1) sensor to the PCV valve cover (2) just enough to remove the MAP sensor. 4. Pull the MAP sensor straight out of PCV valve cover. Installation Procedure 1. Ensure that the seal is installed on the MAP sensor and that the seal is not damaged. 2. Position and install the MAP sensor (1) to the PCV valve cover (2). Ensure that the locking tabs engage to hold the MAP sensor to the PCV valve cover. 3. Connect the MAP sensor electrical connector. 4. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 2930 Lower Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 2931 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 2932 Engine Oil Level Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the engine oil pressure switch electrical connector. 3. Remove the oil pressure switch. Installation Procedure Notice; Refer to Fastener Notice in Service Precautions. 1. Install the engine oil pressure switch. - Tighten the switch to 16 Nm (12 ft. lbs.). 2. Connect the engine oil pressure switch electrical connector. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations Upper Left Rear Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2939 Oxygen Sensor: Diagrams Heated Oxygen Sensor (HO2S) Sensor 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 2940 Heated Oxygen Sensor (HO2S) Sensor 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) 1 Replacement Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 1 Replacement HEATED OXYGEN SENSOR (HO2S) 1 REPLACEMENT TOOLS REQUIRED J 39194 Oxygen Sensor Wrench NOTE: The Heated Oxygen Sensor (HO2S) and the Oxygen Sensor use a permanently attached pigtail and connector. Do not remove this pigtail from the Heated Oxygen Sensor. Damage or the removal of the pigtail or the connector could affect the proper operation of the sensor. Take care when handling the HO2S and the O2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Also avoid using cleaning solvents of any type. Do not drop the HO2S or the O2S. Do not roughly handle the HO2S or the O2S. Removal Procedure NOTE: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. 1. Remove the fuel injector sight shield. 2. Remove the heated oxygen sensor (HO2S) electrical CPA retainer. 3. Disconnect the HO2S wiring harness connector (3) from the HO2S electrical connector (4). 4. Remove the HO2S electrical connector (4) from the fuel injector sight shield bracket (1). IMPORTANT: Remove the oxygen sensor with the engine temperature above 48°C (120°F). Otherwise the oxygen sensors may be difficult to remove. 5. Use the J 39194 to remove the HO2S (2). Installation Procedure NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: A special anti-seize compound is used on the oxygen sensor (1) threads. New service sensors should already have the compound applied to the threads. Coat the threads of a reused sensor with anti-seize compound P/N 12377953 or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) 1 Replacement > Page 2943 1. Install the rear oxygen sensor in the right exhaust manifold. Tighten Use the J 39194 to tighten the HO2S to 41 N.m (30 lb ft). 2. Connect the HO2S electrical connector (4) to the wiring harness connector (3). 3. Install the HO2S electrical connector (4) to the fuel injector sight shield bracket (1). 4. Install the HO2S electrical CPA retainer. 5. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) 1 Replacement > Page 2944 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 2 Replacement HEATED OXYGEN SENSOR (HO2S) 2 REPLACEMENT TOOLS REQUIRED J 39194 Oxygen Sensor Wrench NOTE: The Heated Oxygen Sensor (HO2S) and the Oxygen Sensor use a permanently attached pigtail and connector. Do not remove this pigtail from the Heated Oxygen Sensor. Damage or the removal of the pigtail or the connector could affect the proper operation of the sensor. Take care when handling the HO2S and the O2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Also avoid using cleaning solvents of any type. Do not drop the HO2S or the O2S. Do not roughly handle the HO2S or the O2S. Removal Procedure NOTE: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the HO2S electrical connector retaining tab (1) from the HO2S electrical connector (2). 3. Disconnect the HO2S electrical connector from the HO2S electrical connector (2). 4. Use the J 39194 to remove the HO2S from the exhaust pipe. Installation Procedure NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: A special anti-seize compound is used on the oxygen sensor threads. New service sensors should already have the compound applied to the threads. Coat the threads of a reused sensor with anti-seize compound P/N 12377953 or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) 1 Replacement > Page 2945 1. Install the oxygen sensor (4) to the exhaust pipe. Tighten Use the J 39194 to tighten the oxygen sensor to 41 N.m (30 lb ft). 2. Connect the HO2S connector (4) to the HO2S electrical connector (2). 3. Install the retaining tab (1) to the HO2S electrical connector. 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set Throttle Position Sensor: Customer Interest Engine Controls - Intermittent Chuggle/No DTC's Set Bulletin No.: 05-06-04-058 Date: September 07, 2005 TECHNICAL Subject: Intermittent Chuggle or Fishbite on Light Acceleration or at Highway Speeds with No Diagnostic Trouble Codes (DTCs) (Replace Throttle Position ( TPS) Sensor) Models: 1995-1999 Buick Riviera 1995-2004 Buick Regal 1995-2005 Buick LeSabre, Park Avenue 1997-2005 Buick Century 1995-2001 Chevrolet Lumina 1995-2002 Chevrolet Camaro 1995-2005 Chevrolet Monte Carlo 2000-2005 Chevrolet Impala 1995-1997 Oldsmobile Cutlass Supreme, Ninety Eight 1995-1999 Oldsmobile Eighty Eight 1998-2002 Oldsmobile Intrigue 1995-2002 Pontiac Firebird 1995-2003 Pontiac Grand Prix 1995-2005 Pontiac Bonneville with 3800 V6 Engine (VIN K - RPO L36) Condition Some customers may comment on an intermittent chuggle or fishbite on light acceleration or at steady-state highway speeds (typically 80-105 km/h [50-65 mph]) with no PCM DTCs set. This condition may lead the technician to suspect the TCC circuit or torque converter. Cause This condition may be caused by intermittent operation of the Throttle Position (TPS) Sensor. Correction In observed cases, the Tech 2(R) is not fast enough to consistently detect this condition during a snapshot. It is recommended to use a DVOM set to the min/max recording mode. Connect the DVOM at the TPS connector (positive lead to TPS feedback signal pin and negative lead to TPS ground pin). Duplicate this condition by driving the vehicle. If the voltage dropout (less than 0.45 v) is recorded on the DVOM, replace the TPS sensor and re-evaluate the vehicle before continuing with other driveability or transmission diagnosis. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set > Page 2954 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls Intermittent Chuggle/No DTC's Set Throttle Position Sensor: All Technical Service Bulletins Engine Controls - Intermittent Chuggle/No DTC's Set Bulletin No.: 05-06-04-058 Date: September 07, 2005 TECHNICAL Subject: Intermittent Chuggle or Fishbite on Light Acceleration or at Highway Speeds with No Diagnostic Trouble Codes (DTCs) (Replace Throttle Position ( TPS) Sensor) Models: 1995-1999 Buick Riviera 1995-2004 Buick Regal 1995-2005 Buick LeSabre, Park Avenue 1997-2005 Buick Century 1995-2001 Chevrolet Lumina 1995-2002 Chevrolet Camaro 1995-2005 Chevrolet Monte Carlo 2000-2005 Chevrolet Impala 1995-1997 Oldsmobile Cutlass Supreme, Ninety Eight 1995-1999 Oldsmobile Eighty Eight 1998-2002 Oldsmobile Intrigue 1995-2002 Pontiac Firebird 1995-2003 Pontiac Grand Prix 1995-2005 Pontiac Bonneville with 3800 V6 Engine (VIN K - RPO L36) Condition Some customers may comment on an intermittent chuggle or fishbite on light acceleration or at steady-state highway speeds (typically 80-105 km/h [50-65 mph]) with no PCM DTCs set. This condition may lead the technician to suspect the TCC circuit or torque converter. Cause This condition may be caused by intermittent operation of the Throttle Position (TPS) Sensor. Correction In observed cases, the Tech 2(R) is not fast enough to consistently detect this condition during a snapshot. It is recommended to use a DVOM set to the min/max recording mode. Connect the DVOM at the TPS connector (positive lead to TPS feedback signal pin and negative lead to TPS ground pin). Duplicate this condition by driving the vehicle. If the voltage dropout (less than 0.45 v) is recorded on the DVOM, replace the TPS sensor and re-evaluate the vehicle before continuing with other driveability or transmission diagnosis. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls Intermittent Chuggle/No DTC's Set > Page 2960 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2961 Throttle Position Sensor: Locations Left Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2962 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2963 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2964 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2965 Throttle Position (TP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2966 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Remove the 2 TP sensor screws. 4. Remove the TP sensor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2967 1. Install the TP sensor to the throttle body assembly. 2. Apply thread-locking compound GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the TP sensor screws. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 2 TP sensor screws. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Connect the TP sensor electrical connector. 5. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Lower Right Rear Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 2971 Vehicle Speed Sensor (VSS) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations Left Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2976 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2977 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2978 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2979 Mass Air Flow (MAF) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 2980 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. IMPORTANT: The mass air flow (MAF) sensor is attached to the throttle body assembly. 2. Disconnect the MAF sensor electrical connector (8). 3. Remove the MAF sensor screws (9). 4. Remove the MAF sensor (1). INSTALLATION PROCEDURE 1. Install the MAF sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF sensor screws (9). Tighten Tighten the screws to 3 N.m (27 lb in). 3. Connect the MAF sensor electrical connector (8). 4. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set Throttle Position Sensor: Customer Interest Engine Controls - Intermittent Chuggle/No DTC's Set Bulletin No.: 05-06-04-058 Date: September 07, 2005 TECHNICAL Subject: Intermittent Chuggle or Fishbite on Light Acceleration or at Highway Speeds with No Diagnostic Trouble Codes (DTCs) (Replace Throttle Position ( TPS) Sensor) Models: 1995-1999 Buick Riviera 1995-2004 Buick Regal 1995-2005 Buick LeSabre, Park Avenue 1997-2005 Buick Century 1995-2001 Chevrolet Lumina 1995-2002 Chevrolet Camaro 1995-2005 Chevrolet Monte Carlo 2000-2005 Chevrolet Impala 1995-1997 Oldsmobile Cutlass Supreme, Ninety Eight 1995-1999 Oldsmobile Eighty Eight 1998-2002 Oldsmobile Intrigue 1995-2002 Pontiac Firebird 1995-2003 Pontiac Grand Prix 1995-2005 Pontiac Bonneville with 3800 V6 Engine (VIN K - RPO L36) Condition Some customers may comment on an intermittent chuggle or fishbite on light acceleration or at steady-state highway speeds (typically 80-105 km/h [50-65 mph]) with no PCM DTCs set. This condition may lead the technician to suspect the TCC circuit or torque converter. Cause This condition may be caused by intermittent operation of the Throttle Position (TPS) Sensor. Correction In observed cases, the Tech 2(R) is not fast enough to consistently detect this condition during a snapshot. It is recommended to use a DVOM set to the min/max recording mode. Connect the DVOM at the TPS connector (positive lead to TPS feedback signal pin and negative lead to TPS ground pin). Duplicate this condition by driving the vehicle. If the voltage dropout (less than 0.45 v) is recorded on the DVOM, replace the TPS sensor and re-evaluate the vehicle before continuing with other driveability or transmission diagnosis. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set > Page 2989 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls Intermittent Chuggle/No DTC's Set Throttle Position Sensor: All Technical Service Bulletins Engine Controls - Intermittent Chuggle/No DTC's Set Bulletin No.: 05-06-04-058 Date: September 07, 2005 TECHNICAL Subject: Intermittent Chuggle or Fishbite on Light Acceleration or at Highway Speeds with No Diagnostic Trouble Codes (DTCs) (Replace Throttle Position ( TPS) Sensor) Models: 1995-1999 Buick Riviera 1995-2004 Buick Regal 1995-2005 Buick LeSabre, Park Avenue 1997-2005 Buick Century 1995-2001 Chevrolet Lumina 1995-2002 Chevrolet Camaro 1995-2005 Chevrolet Monte Carlo 2000-2005 Chevrolet Impala 1995-1997 Oldsmobile Cutlass Supreme, Ninety Eight 1995-1999 Oldsmobile Eighty Eight 1998-2002 Oldsmobile Intrigue 1995-2002 Pontiac Firebird 1995-2003 Pontiac Grand Prix 1995-2005 Pontiac Bonneville with 3800 V6 Engine (VIN K - RPO L36) Condition Some customers may comment on an intermittent chuggle or fishbite on light acceleration or at steady-state highway speeds (typically 80-105 km/h [50-65 mph]) with no PCM DTCs set. This condition may lead the technician to suspect the TCC circuit or torque converter. Cause This condition may be caused by intermittent operation of the Throttle Position (TPS) Sensor. Correction In observed cases, the Tech 2(R) is not fast enough to consistently detect this condition during a snapshot. It is recommended to use a DVOM set to the min/max recording mode. Connect the DVOM at the TPS connector (positive lead to TPS feedback signal pin and negative lead to TPS ground pin). Duplicate this condition by driving the vehicle. If the voltage dropout (less than 0.45 v) is recorded on the DVOM, replace the TPS sensor and re-evaluate the vehicle before continuing with other driveability or transmission diagnosis. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls Intermittent Chuggle/No DTC's Set > Page 2995 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2996 Throttle Position Sensor: Locations Left Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2997 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2998 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 2999 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3000 Throttle Position (TP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3001 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Remove the 2 TP sensor screws. 4. Remove the TP sensor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3002 1. Install the TP sensor to the throttle body assembly. 2. Apply thread-locking compound GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the TP sensor screws. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 2 TP sensor screws. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Connect the TP sensor electrical connector. 5. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3007 Right Middle Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3008 Camshaft Position (CMP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3009 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The camshaft position (CMP) sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor does not directly affect the operation of the ignition system. The CMP sensor information is used by the powertrain control module (PCM) to determine the position of the valve train relative to the CKP. By monitoring the CMP and CKP signals the PCM can accurately time the operation of the fuel injectors. The CMP sensor shares 12-volt and low reference circuits with the CKP sensor. The CMP signal circuit is input to the ICM. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3010 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the coolant recovery reservoir. 2. Remove the drive belt. 3. Disconnect the electrical connector (2) from the camshaft position sensor (1). 4. Remove the camshaft position sensor bolt. 5. Remove the camshaft position sensor from the engine front cover. INSTALLATION PROCEDURE 1. Install the camshaft position sensor to the engine front cover. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 3011 2. Install the camshaft position sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 3. Connect the electrical connector (2) to the camshaft position sensor (1). 4. Install the drive belt. 5. Install the coolant recovery reservoir. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3015 Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3016 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3017 Camshaft Position (CKP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3018 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSORS The crankshaft position (CKP) sensor has a 4-wire harness connector that plugs into the CKP sensor and connects to the ignition control module (ICM). The CKP sensor contains 2 hall-effect switches in 1 housing, and shares a magnet between the switches. The magnet and each hall-effect switch are separated by an air gap. A hall-effect switch is a solid state switching device that produces a digital ON/OFF pulse when a rotating element passes the sensor pick-up and interrupts the magnetic field of the sensor. The rotating element is called an interrupter ring or blade. There are two interrupter rings built into the crankshaft balancer. The outer ring and the outer switch provide the ICM with 18X signals or 18 identical pulses per crankshaft revolution. The inner ring and the inner switch provide the ICM with 3 pulses per revolution, each 1 of different duration. This is called the sync pulse. Each sync pulse represents a pair of companion cylinders. The ICM supplies a 12-volt and a low reference circuit to the CKP sensor, which is also shared by the camshaft position (CMP) sensor. The 18X reference pulses are passed from the CKP sensor to the ICM on the CKP sensor 1 signal circuit. The sync pulses are passed from the CKP sensor to the ICM on the CKP sensor 2 signal circuit. The ICM uses the 18X and sync pulses to determine the crankshaft position by counting how many ON-OFF 18X pulses occur during a sync pulse. With this dual interrupter ring arrangement the ICM can identify the correct pair of cylinders to fire within as little as 120 degrees of crankshaft rotation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3019 Crankshaft Position Sensor: Testing and Inspection CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The ignition control module (ICM) monitors the crankshaft position (CKP) sensor sync signal when the engine is cranking. The CKP sync signal is passed from the CKP sensor to the ICM on the CKP sensor 2 signal circuit. The CKP sync signal is used to determine the correct cylinder pair and initiate the ignition coil firing sequence. The 18X reference pulses are passed from the CKP sensor to the ICM on the CKP sensor 1 signal circuit. The 18X reference pulses are used for fuel injection and ignition control. After the ICM receives both signals, the ICM passes the 18X and 3X reference signals to the powertrain control module (PCM). The camshaft position sensor and the CKP sensor share a 12-volt reference and a low reference circuit. The CKP sensor consists of the following circuits: A 12-volt reference circuit - A low reference circuit - A CKP sensor 1 signal circuit - A CKP sensor 2 signal circuit TEST Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3020 Steps 4-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3021 Steps 8-14 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3022 Steps 15-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3023 Steps 21-26 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3024 Steps 27-28 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 3025 Steps 29-31 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 4.1. Accelerate to wide open throttle (WOT). 4.2. Release throttle when fuel cut-off occurs. 4.3. Observe fuel cut-off specification for applicable engine. 4.4. Engine should not accelerate beyond calibrated RPM value. 4.5. Release throttle immediately if value is exceeded. 4.6. Block drive wheels. 4.7. Set parking brake. 4.8. DO NOT apply brake pedal. 4.9. Cycle ignition from OFF to ON. 4.10. Apply and hold brake pedal. 4.11. Start and idle engine. 4.12. Turn A/C OFF. 4.13. Vehicle must remain in Park or Neutral. 4.14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure.The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - Crankshaft position (CKP) sensors activity - If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity - If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool and perform the following: IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 5.1. Accelerate to WOT. 5.2. Release when fuel cut-off occurs. 5.3. Test in progress. 6. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 . If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC. 7. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set Engine replacement - PCM replacement - A harmonic balancer replacement - Crankshaft replacement - CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3028 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the right splash shield cover. 4. Remove the crankshaft balancer. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the CKP sensor shield (1). 7. Remove the CKP sensor bolts. 8. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3029 1. Position the CKP sensor to the block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolts. Tighten Tighten the bolts to 30 N.m (22 lb ft) 3. Install the CKP sensor shield (1). 4. Connect the CKP sensor electrical connector. 5. Install the crankshaft balancer. 6. Install the right splash shield cover. 7. Lower the vehicle. 8. Connect the negative battery cable. 9. Perform the Crankshaft Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder Replacement Removal Procedure Important: Perform the body control module (BCM) theft deterrent relearn procedure whenever you replace the ignition switch lock cylinder. 1. Disconnect the negative battery cable. 2. Remove the instrument panel (I/P) cluster trim plate. 3. Insert the key and turn the ignition lock cylinder to the ON/RUN position. 4. Using a small curved tool or an L-shaped hex wrench, depress and hold the detent on the ignition lock cylinder. Access the detent by placing the tool through the I/P opening to the right of the ignition switch. If you cannot locate the detent with the tool, lower the ignition switch away from the I/P. Refer to Ignition Switch Replacement. 5. Using the key as an aid, pull to remove the lock cylinder from the switch. 6. Remove the key from the lock cylinder. 7. If the cylinder does not rotate or is seized, follow the procedure in the ignition switch replacement. Refer to Ignition Switch Replacement. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 3034 1. Code the ignition lock cylinder, if necessary. Refer to Key and Lock Cylinder Coding in General Information. 2. Insert the key and turn the lock cylinder to the ON/RUN position. 3. Position the lock cylinder to the ignition switch. Press the cylinder into place. If you turned the key slightly while removing the lock cylinder, you may have to align the white colored ignition switch rotor (1) with the lock cylinder (2). You can rotate the ignition switch rotor (1) with your finger. 4. Turn the key to the OFF position and remove the key. 5. Install the I/P cluster trim plate. 6. Connect the negative battery cable. 7. If you installed a new lock cylinder, perform the BCM theft deterrent relearn procedure. Refer to Body Control Module (BCM) Programming/RPO Configuration in Body Control System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Lower Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3038 Rear Middle Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3039 Knock Sensor: Diagrams Knock Sensor (KS) 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3040 Knock Sensor (KS) 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 3041 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This KS system uses one or two broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement Knock Sensor: Service and Repair Knock Sensor (KS) 1 Replacement KNOCK SENSOR (KS) 1 REPLACEMENT REMOVAL PROCEDURE CAUTION: Hot engine coolant may cause severe burns. Although the cooling system has been drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of the knock sensor. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Disconnect the knock sensor electrical connector (2). 4. Remove the knock sensor (1). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. 1. Install the knock sensor (1). Tighten Tighten the knock sensor to 19 N.m (14 lb ft). 2. Connect the knock sensor electrical connector (2). 3. Lower the vehicle. 4. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement > Page 3044 Knock Sensor: Service and Repair Knock Sensor (KS) 2 Replacement KNOCK SENSOR (KS) 2 REPLACEMENT REMOVAL PROCEDURE CAUTION: Hot engine coolant may cause severe burns. Although the cooling system has been drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of the knock sensor. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Remove the bolts (2) from the knock sensor heat shield (1). 4. Disconnect the knock sensor electrical connector (3) from the knock sensor. 5. Remove the knock sensor (4). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. 1. Install the knock sensor (4). Tighten Tighten the knock sensor to 19 N.m (14 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement > Page 3045 2. Install the knock sensor heat shield. Tighten Tighten the bolts to 60 N.m (44 lb ft). 3. Connect the knock sensor electrical connector. 4. Lower the vehicle. 5. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 364-405 kPa (53-59 psi) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable.A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Remove the fuel injector sight shield. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Install the J 34730-1A to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3052 3. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gage. 7. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container. Open the bleed valve in order to bleed the fuel system pressure. 2. Place a shop towel under the fuel pressure gage in order to catch any remaining fuel spillage. 3. Remove the fuel pressure gage from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3053 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST DESCRIPTION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3054 Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3055 Steps 4-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3056 Steps 8-9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3057 Steps 10-11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3058 Steps 12-15 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3059 Steps 16-17 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3060 Steps 18-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3061 Steps 21-25 The numbers below refer to the step numbers on the diagnostic table. 2. This step verifies that the fuel pump is operating. 4. This step tests for an internal fuel leak. If the fuel pressure decreases during this test, an internal loss of pressure is indicated. 6. This step tests the fuel pressure regulator. The fuel pressure regulator is controlled by engine vacuum. With engine vacuum applied, the pressure should decrease by the specified value. 9. This step inspects the fuel pressure regulator for a fuel leak from the vacuum port. If fuel leaks from the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator. 10. This step tests for a loss of fuel pressure between the shut-off adapter on the fuel feed pipe and the fuel pump. 11. This step tests for a leaking fuel injector, or fuel pressure regulator. If the fuel pressure remains constant during this test, the fuel injectors are not leaking fuel. 14. This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, a restriction in the fuel return pipe is indicated. 16. This step determines if the fuel pressure regulator, or the fuel pump, is the cause of the low fuel pressure. If the pressure rises above the specified value, the fuel pump is OK. 18. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Inspect all fuel pump electrical circuits thoroughly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER INTAKE DUCT REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector (3). 2. Remove the IAT sensor with a twisting and pulling motion. 3. Loosen the air cleaner intake duct clamp. 4. Remove the air cleaner intake duct from the air cleaner cover. 5. Remove the air cleaner intake duct from the throttle body. INSTALLATION PROCEDURE 1. Install the air cleaner intake duct to the throttle body. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the air cleaner intake duct to the air cleaner cover. Tighten Tighten the air cleaner duct clamp to 2 N.m (18 lb in). 3. Install the IAT sensor. 4. Connect the IAT sensor electrical connector (3). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3077 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Filter Element: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3083 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 3084 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner intake duct . 2. Unclip the 2 air cleaner cover retaining clamps. 3. Remove the air cleaner housing cover (5). 4. Remove the air filter element (6). 5. Inspect the air cleaner housing cover (5), the seal assembly, and the air cleaner intake duct for damage. If a problem is found, replace as necessary. INSTALLATION PROCEDURE 1. Install the air filter element (6). 2. Install the air cleaner housing cover (5) and clip the housing cover retaining clamps. 3. Install the air cleaner intake duct. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable.A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Remove the fuel injector sight shield. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Install the J 34730-1A to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3090 3. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gage. 7. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container. Open the bleed valve in order to bleed the fuel system pressure. 2. Place a shop towel under the fuel pressure gage in order to catch any remaining fuel spillage. 3. Remove the fuel pressure gage from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3091 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage RELIEF PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the fuel injector sight shield. 3. Loosen the fuel filler cap to relieve tank vapor pressure. 4. Connect the J 34730-1A to the fuel pressure connection. Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gage in order to avoid spillage. 5. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 6. Drain any fuel remaining in the fuel pressure gage into an approved container. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Refer to the list below for items to be inspected. 1. Inspect for correct routing of the spark plug wires. Improper routing may cause cross-firing. 2. Inspect each wire for any signs of cracks or splits in the wire. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal both the wire and the component connected to the wire should be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 3095 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT TOOLS REQUIRED J 38491 Spark Plug Boot Removal Tool REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Remove the spark plug wires (2, 4, 6) from the spark plugs at the rear of the engine using the following steps: 2.1. Note the position of the spark plug wires before removing the wires. 2.2. Twist the spark plug boot 1/2 turn before removing the boot. 2.3. Gently pry the heat shield up from spark plugs using the J 38491. 2.4. Remove the spark plug wire from the spark plugs at rear of the engine. 3. Remove the spark plug wires (1, 3, 5) from the spark plugs at the front of the engine using the following steps: 3.1. Note the position of the spark plug wires before removing the wires. 3.2. Twist the spark plug boot 1/2 turn before removing the boot. 3.3. Gently pry the heat shield up from spark plugs using the J 38491. 3.4. Remove the spark plug wires form the spark plugs at the front of the engine. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 3096 4. Remove the spark plug wires from the ignition coils. 5. Remove the spark plug wire retaining clips from the rear, front and top of the engine. 6. Remove the spark plug wires from the engine. 7. When replacing the spark plug wires transfer any of the following: - Boot heat shields - Spark plug wire conduit - Spark plug wire retaining clips INSTALLATION PROCEDURE 1. Position the spark plug wires to the engine. 2. Install the spark plug wire retaining clips from the rear, front and top of the engine. 3. Install the spark plug wires to the ignition coil in the proper position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Testing and Inspection > Page 3097 4. Install the spark plug wires (1, 3, 5) to the spark plugs in the proper position at the front of the engine. 5. Install the spark plug wires (2, 4, 6) to the spark plugs in the proper position at the rear of the engine. 6. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark Plug Gap ................................................................................................................................... ..................................................... 0.060 in. (1.52 mm) Spark Plug Torque ........................................ ........................................................................................................................................ 11.0 lb. ft. (15.0 Nm) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3101 Spark Plug: Application and ID SPARK PLUG AC Delco P/N ...................................................................................................................................... .................................................................. 41-921 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3102 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION SPARK PLUG USAGE - Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. - Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3103 - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications . An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. - A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION - Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures - Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element Incorrect combustion - Reduced ignition system voltage output - Weak coils Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3104 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications > Page 3105 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wires from the spark plugs. 2. Remove the spark plugs from the engine. INSTALLATION PROCEDURE 1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to the gap specifications. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the spark plugs to the engine. Tighten If installing the spark plugs to a new cylinder tighten the plugs to 27N.m (20 lb ft). - If installing the spark plugs to an existing cylinder tighten the plugs to 15N.m(11 lb ft). 1. Connect the spark plug wires to the spark plugs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications Compression Check: Specifications No cylinder reading should be less than 689 kPa (100 psi) The lowest reading should not be less than 70 percent of the highest reading. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check > System Information > Specifications > Page 3109 Compression Check: Testing and Inspection Engine Compression Test - Tools Required J 38722 Compression Tester A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the head gasket. 1. Run the engine until it reaches normal operating temperature. The battery must be at or near full charge. 2. Turn the engine OFF. Important: Remove the Powertrain Control Module (PCM) and the ignition fuses from the I/P fuse block. 3. Disable the ignition. 4. Disable the fuel systems. 5. Remove the spark plugs from all the cylinders. 6. Remove the air duct from the throttle body. 7. Block the throttle plate in the open position. 8. Measure the engine compression, using the following procedure: 8.1. Firmly install J 38722 to the spark plug hole. 8.2. Have an assistant crank the engine through at least four compression strokes in the testing cylinder. 8.3. Check and record the readings on J 38722 at each stroke. 8.4. Disconnect J 38722. 8.5. Repeat the compression test for each cylinder. 9. Record the compression readings from all of the cylinders. - The lowest reading should not be less than 70 percent of the highest reading. - No cylinder reading should be less than 689 kPa (100 psi). 10. The following are examples of the possible measurements: - When the compression measurement is normal, the compression builds up quickly and evenly to the specified compression on each cylinder. - When the compression is low on the first stroke and tends to build up on the following strokes, but does not reach the normal compression, or if the compression improves considerably with the addition of three squirts of oil, the piston rings may be the cause. - When the compression is low on the first stroke and does not build up in the following strokes, or the addition of oil does not affect the compression, the valves may be the cause. - When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the head gasket may be the cause. 11. Remove the block from the throttle plate. 12. Install the air duct to the throttle body. 13. Install the spark plugs. 14. Install the Powertrain Control Module (PCM) fuse. 15. Install the ignition fuse to the I/P fuse block. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations Left Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3114 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3115 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3116 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3117 Mass Air Flow (MAF) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3118 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. IMPORTANT: The mass air flow (MAF) sensor is attached to the throttle body assembly. 2. Disconnect the MAF sensor electrical connector (8). 3. Remove the MAF sensor screws (9). 4. Remove the MAF sensor (1). INSTALLATION PROCEDURE 1. Install the MAF sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF sensor screws (9). Tighten Tighten the screws to 3 N.m (27 lb in). 3. Connect the MAF sensor electrical connector (8). 4. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Intake Air Temperature (IAT) Sensor: Locations Intake Air Temperature Sensor (IAT) is in the air induction tube. 3. Intake Air Temperature (IAT) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature (IAT) Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3124 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3125 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3126 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3127 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3128 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3129 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3130 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3131 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3132 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3133 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3134 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3135 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3136 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3137 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3138 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3139 Intake Air Temperature (IAT) Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3140 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3141 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3142 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3143 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3144 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3145 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3146 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3147 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3148 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3149 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3150 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3151 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3152 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3153 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3154 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3155 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3156 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3157 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3158 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3159 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3160 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3161 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3162 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3163 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3164 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3165 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3166 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3167 Intake Air Temperature (IAT) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 3168 Intake Air Temperature (IAT) Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector. 2. Remove the IAT sensor (3) with a twisting and pulling motion. INSTALLATION PROCEDURE 1. Install the IAT sensor (3). 2. Connect the IAT sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: Customer Interest BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 3177 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: All Technical Service Bulletins BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 3183 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3193 Behind Left Side Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 Body Control Module: Diagrams Body Control Module (BCM) C1 Body Control Module, C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3196 Body Control Module, C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3197 Body Control Module, C1 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3198 Body Control Module: Diagrams Body Control Module (BCM) C2 Body Control Module, C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3199 Body Control Module, C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3200 Body Control Module: Diagrams Body Control Module (BCM) C3 Body Control Module, C3 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3201 Body Control Module, C3 Part 2 Body Control Module, C3 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 3202 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. The BCM has five basic modes (disarmed, standby, delayed, armed, and alarm) for operating the CTD system. The different modes are described below. 1. The BCM has the CTD system in a disarmed mode until the following conditions are detected: - Ignition key turned to the OFF position. - Any door open. - Doors locked by either the power door lock switch or the LOCK button on the transmitter. 2. The BCM enters the standby mode when the above conditions are detected. In standby mode, the BCM commands the SECURITY indicator to flash. If all the doors are closed and the LOCK button on the transmitter is used, the BCM enters the delayed mode. 3. When the last door is closed, the BCM enters the delayed mode for 30 seconds. In delayed mode the BCM commands the SECURITY indicator to illuminate ON steady. 4. After 30 seconds, the BCM enters the armed mode. Any forced entry activates the alarm mode. 5. When the BCM detects a forced entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active.The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. The body control module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(TM) data from the Passlock(TM) sensor. If the Passlock(TM) data is correct, the BCM will send a class 2 message to the PCM to enable the fuel injectors and crank relay. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(TM) data, the VTD system will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors and crank relay for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(TM) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable and crank relay enable signal to the PCM. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION During body control module (BCM) related service, the procedures below are designated to set-up the BCM correctly. Before you start, read these procedures carefully and completely. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: The BCM will not function properly if the Setup New BCM procedure is not performed. - Make sure the battery is fully charged before performing the setup procedure. - Make sure all disconnected devices and connectors have been reconnected - Perform the Theft Deterrent Re-learn procedure after successfully finishing the Setup New BCM procedure. Refer to Programming Theft Deterrent System Components in Theft Deterrent. If the Theft Deterrent Re-learn procedure is not performed after a BCM replacement, the following conditions may occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. 1. Connect a scan tool to the data link connector (DLC). 2. Turn the ignition switch ON. 3. Select Diagnostics and input all of the required data when prompted by the scan tool. 4. Select BODY CONTROL MODULE. 5. Select SPECIAL FUNCTIONS. 6. Select New VIN and input all required data. 7. Exit back to the SPECIAL FUNCTIONS menu. 8. Select BCM REPROGRAMMING. 9. The scan tool will display DO YOU WANT TO SETUP A BODY CONTROL MODULE? At the prompt, select SETUP BCM hotspot on the scan tool. 10. The scan tool will display: NOW SETTING UP THE NEW BODY CONTROL MODULE. 11. When the BCM has been setup successfully, the scan tool will display: BODY CONTROL MODULE SETUP IS COMPLETE. 12. Exit back to the SPECIAL FUNCTIONS menu. 13. Select Point of Sale in this menu. 14. Input all of the required data when prompted by the scan tool. 15. Exit back to the SET OPTIONS menu. 16. Select Option Configuration. 17. Input all of the required data when prompted by the scan tool. 18. When the BCM, VIN, Point of Sale and Option Configuration have been entered, proceed with the Theft Deterrent Re-learn procedure. 19. If the scan tool displays UNABLE TO PROGRAM BCM. BCM IS SECURED, then the BCM must be replaced and this procedure must be repeated on a new BCM. NOTE: After the above procedure has been completed, personalization of the BCM defaults to a default setting. Inform the customer that the personalization settings must be set again. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 3205 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: You must perform the new body control module (BCM) setup when replacing the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 1. Disconnect the battery ground (negative) cable. 2. Remove the left instrument panel insulator. 3. Disconnect the BCM electrical connectors (2,3,4). 4. Remove the BCM (1). INSTALLATION PROCEDURE 1. Install the body control module (BCM) (1). 2. Connect the BCM electrical connectors (2,3,4). 3. Install the left instrument panel insulator. 4. Connect the battery ground (negative) cable. 5. Perform the new BCM setup. Refer to Body Control Module (BCM) Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3209 Right Middle Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3210 Camshaft Position (CMP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3211 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The camshaft position (CMP) sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor does not directly affect the operation of the ignition system. The CMP sensor information is used by the powertrain control module (PCM) to determine the position of the valve train relative to the CKP. By monitoring the CMP and CKP signals the PCM can accurately time the operation of the fuel injectors. The CMP sensor shares 12-volt and low reference circuits with the CKP sensor. The CMP signal circuit is input to the ICM. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3212 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the coolant recovery reservoir. 2. Remove the drive belt. 3. Disconnect the electrical connector (2) from the camshaft position sensor (1). 4. Remove the camshaft position sensor bolt. 5. Remove the camshaft position sensor from the engine front cover. INSTALLATION PROCEDURE 1. Install the camshaft position sensor to the engine front cover. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3213 2. Install the camshaft position sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 3. Connect the electrical connector (2) to the camshaft position sensor (1). 4. Install the drive belt. 5. Install the coolant recovery reservoir. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3217 Engine Coolant Temperature (ECT) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3218 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Partially drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the thermostat housing. 3. Disconnect the ECT sensor electrical connector. 4. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. 1. Coat the threads with sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3219 3. Connect the ECT sensor electrical connector. 4. Install the thermostat housing. 5. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3223 Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3224 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3225 Camshaft Position (CKP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3226 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSORS The crankshaft position (CKP) sensor has a 4-wire harness connector that plugs into the CKP sensor and connects to the ignition control module (ICM). The CKP sensor contains 2 hall-effect switches in 1 housing, and shares a magnet between the switches. The magnet and each hall-effect switch are separated by an air gap. A hall-effect switch is a solid state switching device that produces a digital ON/OFF pulse when a rotating element passes the sensor pick-up and interrupts the magnetic field of the sensor. The rotating element is called an interrupter ring or blade. There are two interrupter rings built into the crankshaft balancer. The outer ring and the outer switch provide the ICM with 18X signals or 18 identical pulses per crankshaft revolution. The inner ring and the inner switch provide the ICM with 3 pulses per revolution, each 1 of different duration. This is called the sync pulse. Each sync pulse represents a pair of companion cylinders. The ICM supplies a 12-volt and a low reference circuit to the CKP sensor, which is also shared by the camshaft position (CMP) sensor. The 18X reference pulses are passed from the CKP sensor to the ICM on the CKP sensor 1 signal circuit. The sync pulses are passed from the CKP sensor to the ICM on the CKP sensor 2 signal circuit. The ICM uses the 18X and sync pulses to determine the crankshaft position by counting how many ON-OFF 18X pulses occur during a sync pulse. With this dual interrupter ring arrangement the ICM can identify the correct pair of cylinders to fire within as little as 120 degrees of crankshaft rotation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3227 Crankshaft Position Sensor: Testing and Inspection CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The ignition control module (ICM) monitors the crankshaft position (CKP) sensor sync signal when the engine is cranking. The CKP sync signal is passed from the CKP sensor to the ICM on the CKP sensor 2 signal circuit. The CKP sync signal is used to determine the correct cylinder pair and initiate the ignition coil firing sequence. The 18X reference pulses are passed from the CKP sensor to the ICM on the CKP sensor 1 signal circuit. The 18X reference pulses are used for fuel injection and ignition control. After the ICM receives both signals, the ICM passes the 18X and 3X reference signals to the powertrain control module (PCM). The camshaft position sensor and the CKP sensor share a 12-volt reference and a low reference circuit. The CKP sensor consists of the following circuits: A 12-volt reference circuit - A low reference circuit - A CKP sensor 1 signal circuit - A CKP sensor 2 signal circuit TEST Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3228 Steps 4-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3229 Steps 8-14 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3230 Steps 15-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3231 Steps 21-26 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3232 Steps 27-28 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3233 Steps 29-31 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 4.1. Accelerate to wide open throttle (WOT). 4.2. Release throttle when fuel cut-off occurs. 4.3. Observe fuel cut-off specification for applicable engine. 4.4. Engine should not accelerate beyond calibrated RPM value. 4.5. Release throttle immediately if value is exceeded. 4.6. Block drive wheels. 4.7. Set parking brake. 4.8. DO NOT apply brake pedal. 4.9. Cycle ignition from OFF to ON. 4.10. Apply and hold brake pedal. 4.11. Start and idle engine. 4.12. Turn A/C OFF. 4.13. Vehicle must remain in Park or Neutral. 4.14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure.The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - Crankshaft position (CKP) sensors activity - If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity - If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool and perform the following: IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 5.1. Accelerate to WOT. 5.2. Release when fuel cut-off occurs. 5.3. Test in progress. 6. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 . If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC. 7. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set Engine replacement - PCM replacement - A harmonic balancer replacement - Crankshaft replacement - CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3236 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the right splash shield cover. 4. Remove the crankshaft balancer. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the CKP sensor shield (1). 7. Remove the CKP sensor bolts. 8. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3237 1. Position the CKP sensor to the block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolts. Tighten Tighten the bolts to 30 N.m (22 lb ft) 3. Install the CKP sensor shield (1). 4. Connect the CKP sensor electrical connector. 5. Install the crankshaft balancer. 6. Install the right splash shield cover. 7. Lower the vehicle. 8. Connect the negative battery cable. 9. Perform the Crankshaft Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Timing Ring > Component Information > Description and Operation Crankshaft Position Timing Ring: Description and Operation CRANKSHAFT BALANCE INTERRUPTER RING Each interrupter ring has blades and windows that either block the magnetic field or allow it to close one of the hall-effect switches. The outer hall-effect switch sends a pulse called the 18X reference signal. The outer interrupter ring has 18 evenly spaced blades and windows. The 18X reference signal produces 18 ON-OFF pulses per crankshaft revolution. The inner hall-effect switch sends a pulse called the sync signal. The inner interrupter ring has 3 unevenly spaced blades and windows of different widths. The sync signal produces 3 different length ON-OFF pulses per crankshaft revolution. When the sync interrupter ring window is between the magnet and the inner switch, the magnetic field will cause the sync hall-effect switch to ground the supplied voltage from the ICM. The 18X interrupter ring and the hall-effect switch react similarly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations Data Link Connector: Locations Lower Center Of Instrument Panel (Without RPO Code 9C1/9C3) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 3244 Behind Center Left Side Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 3245 Lower Center Of Instrument Panel (Without RPO Code 9C1/9C3) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector > Component Information > Locations > Page 3246 Data Link Connector: Service and Repair DATA LINK CONNECTOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the screws from the data link connector. 2. Reposition the data link connector from the instrument panel. INSTALLATION PROCEDURE 1. Position the data link connector to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws to the data link connector. Tighten Tighten the data link connector screws to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3251 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3252 Left Front Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 Engine Control Module: Diagrams Powertrain Control Module, C1 Powertrain Control Module, C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 3255 Powertrain Control Module, C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 3256 Powertrain Control Module, C1 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 3257 Powertrain Control Module, C1 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 3258 Engine Control Module: Diagrams Powertrain Control Module, C2 Powertrain Control Module, C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 3259 Powertrain Control Module, C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 3260 Powertrain Control Module, C2 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 3261 Powertrain Control Module, C2 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module Engine Control Module: Description and Operation Powertrain Control Module POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION The PCM communicates with the BCM over the Class 2 serial data line. When the BCM determines an incorrect password, it sends a Class 2 serial data password to the PCM in order to disable the crank relay and fuel injection system. If the BCM receives the expected voltage from the Passlock(TM) sensor, the BCM sends a class 2 serial data password to the PCM in order to enable the crank relay and fuel injection system. The PCM then allows the vehicle to start normally. POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module > Page 3264 The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the PCM, allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e. misfire). WARM-UP CYCLE The PCM uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160 °F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The PCM is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module > Page 3265 Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the MIL or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. The last test may have run during a previous ignition cycle if an A or B type DTC is displayed. For type C DTCs, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MIL Request: Indicates that this DTC is currently requesting the MIL. This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History: Indicates that the DTC is stored in the PCM History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear): DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module > Page 3266 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM maintains proper spark and fuel injection timing for all driving conditions. Ignition control (IC) spark timing is the method the PCM uses to control spark advance. To provide optimum driveability and emissions, the PCM monitors input signals from the following components to calculate ignition spark timing: The ignition control module (ICM) - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) The following describes the PCM to ICM circuits: Low resolution engine speed signal-3 X reference-PCM input-from the ICM. The 3X reference signal is produced by the ICM. The PCM uses this signal to calculate engine RPM and crankshaft position above 1,200 RPM. The PCM also uses the pulses on this circuit to initiate fuel injector operation. The PCM compares the number of 3X pulses to the number of 18X and cam pulses. If the number of 3X pulses are incorrect while the engine is cranking or running, the PCM will set a DTC. The engine will continue to start and run normally using the 18X reference signal. - Medium resolution engine speed signal-18 X reference-PCM input-from the ICM. The 18 X reference signal is used to accurately control spark timing at low RPM and allow ignition control (IC) operation during cranking. The ICM calculates the 18X reference signal by filtering the CKP sensor 18X pulses when the engine is running and the CKP sync pulses are being received. Below 1,200 RPM, the PCM is monitoring the 18X reference signal and using the 18X signal as the reference for ignition timing advance. The PCM compares the number of 18X pulses to the number of 3X and cam pulses. If the number of 18X pulses are incorrect while the engine is cranking or running, the PCM will set a DTC. The engine will continue to start and run normally using the 3X reference signal. - Camshaft position-PCM input-from the ICM. The PCM uses this signal to determine the position of the cylinder #1 piston during the pistons power stroke. This signal is used by the PCM to calculate true sequential fuel injection (SFI) mode of operation. The PCM compares the number of CAM pulses to the number of 18 X and 3 X reference pulses. If the number of 18 X and 3 X reference pulses occurring between CAM pulses is incorrect, or if no CAM pulses are received while the engine is running, the PCM will set a DTC. If the CAM signal is lost while the engine is running the fuel injection system will shift to a calculated sequential fuel injection mode based on the last CAM pulse, and the engine will continue to run. The engine can be re-started and will run in the calculated sequential mode as long as the condition is present with a 1 in 6 chance of being correct. - Low reference-PCM input-this is a ground circuit for the digital RPM counter inside the PCM, but the wire is connected to engine ground only through the ICM. This circuit assures there is no ground drop between the PCM and ICM. - IC timing signal-PCM output-to the ICM. The ICM controls spark timing while the engine is cranking, this is called bypass mode. Once the PCM receives 3 X reference signals from the ICM, the PCM applies 5 volts to the IC timing signal circuit allowing the ICM to switch spark advance to PCM control. - IC timing control-PCM output-to the ICM. The IC output circuitry of the PCM sends out timing signals to the ICM on this circuit. When in the Bypass Mode, the ICM grounds these signals. When in the IC Mode, the signals are sent to the ICM to control spark timing. - Default mode due to a system failure The other mode is the IC mode during which the PCM is receiving the 18X and the 3X reference pulses from the CKP sensor and is supplying 5 volts to the IC timing signal circuit. This allow the PCM to accurately control spark timing for all driving conditions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3267 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for PCM replacement, inspect the PCM first to see if the replacement is the correct part. If the PCM is faulty, remove the PCM and install the new service PCM. The new service PCM will not be programmed. You must program the new PCM. DTC P0602 indicates the EEPROM is not programmed or has malfunctioned. NOTE: - Do not touch the connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage to the PCM. - Turn the ignition OFF when installing or removing the PCM connectors and disconnecting or reconnecting the power to the PCM (battery cable, PCM pigtail, PCM fuse, jumper cables, etc.) in order to prevent internal PCM damage. Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the left front inner fender brace. 3. Remove the air cleaner intake duct. 4. Remove the air cleaner housing cover screws (2). 5. Remove the air cleaner housing cover (1). 6. Without disconnecting the PCM electrical connectors, remove the PCM and the wiring harness from the air cleaner housing assembly (3). 7. Disconnect the PCM electrical connectors and remove the PCM. Installation Procedure NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the PCM to the PCM electrical connectors. Tighten Tighten the connectors to 8 N.m (71 lb in). 2. Install the PCM and the wiring harness to the air cleaner housing assembly (3). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3268 3. Install the air cleaner housing cover (1). 4. Install the air cleaner housing cover screws (2). Tighten Tighten the screws to 4 N.m (35 lb in). 5. Install the air cleaner intake duct. 6. Install the left front inner fender brace. 7. Connect the negative battery cable. 8. The new PCM must be programmed. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Fuel Pump And Sender Assembly Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3272 Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3273 Fuel Level Sensor: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Remove the fuel sender assembly. 2. Disconnect the fuel level sensor electrical connector. 3. Remove the fuel level sensor (5) from the fuel sender assembly. INSTALLATION PROCEDURE 1. Install the fuel level sensor (5) to the fuel sender assembly. 2. Connect the fuel level sensor electrical connector. 3. Install the fuel sender assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations Fuel Pump And Sender Assembly Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3277 Fuel Tank Pressure (FTP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3278 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3279 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank pressure sensor (7) from the fuel sender assembly (1). 2. Disconnect the negative battery cable. 3. Remove the fuel sender assembly. INSTALLATION PROCEDURE 1. Install the new fuel tank pressure sensor (7) to the fuel sender assembly (1). 2. Install the fuel sender assembly. 3. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams Idle Air Control (IAC) Valve Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 3283 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection IDLE AIR CONTROL (IAC) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The engine idle speed is controlled by the idle air control (IAC) valve. The IAC valve is on the throttle body. The IAC valve pintle moves in and out of an idle air passage bore to control air flow around the throttle plate. The IAC valve consists of a movable pintle, driven by a gear attached to an electric motor called a stepper motor. The stepper motor is capable of highly accurate rotation, or of movement, called steps. The stepper motor has 2 separate windings that are called coils. Each coil is supplied current by two circuits from the powertrain control module (PCM). When the PCM changes polarity of a coil, the stepper motor moves one step. The PCM uses a predetermined number of counts to determine the IAC pintle position. Observe IAC counts with a scan tool. The IAC counts will increment up or down as the PCM attempts to change the IAC valve pintle position. An IAC Reset will occur when the ignition key is turned OFF. First, the PCM will seat the IAC pintle in the idle air passage bore. Second, the PCM will retract the pintle a predetermined number of counts to allow for efficient engine start-up. If the engine idle speed is out of range for a calibrated period of time, an idle speed diagnostic trouble code (DTC) sets. DIAGNOSTIC AIDS Inspect for the following conditions: High resistance in an IAC valve control circuit - The correct positive crankcase ventilation (PCV) valve, properly installed and proper operation of the PCV valve - Proper operation and installation of all air intake components - Proper installation and operation of the mass air flow (MAF) sensor, if equipped - A tampered with or damaged throttle stop screw - A tampered with or damaged throttle plate, throttle shaft, throttle linkage, or cruise control linkage, if equipped - A skewed high throttle position (TP) sensor - Excessive deposits in the IAC passage or on the IAC pintle - Excessive deposits in the throttle bore or on the throttle plate - Vacuum leaks - A high or unstable idle condition could be caused by a non-IAC system problem that can not be overcome by the IAC valve. Refer to Symptoms - Computers and Control Systems. See: Testing and Inspection/Symptom Related Diagnostic Procedures - If the problem is determined to be intermittent, refer to Intermittent Conditions. See: Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies TEST DESCRIPTION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 3284 Steps 1-2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 3285 Steps 3-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 3286 Steps 6-8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 3287 Steps 9-10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 3288 Step 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 3289 Steps 12-13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 3290 Steps 14-19 The numbers below refer to the step numbers on the diagnostic table. 5. This test will determine the ability of the PCM and IAC valve control circuits to control the IAC valve. 7. This test will determine the ability of the PCM to provide the IAC control valve circuits with a ground. On a normally operating system, the test lamp should not flash while the IAC Counts are incrementing. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 3291 Idle Speed/Throttle Actuator - Electronic: Service and Repair IDLE AIR CONTROL (IAC) VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Disconnect the idle air control valve (IAC) electrical connector. 3. Remove the IAC valve screws. 4. Remove the IAC valve. 5. Remove the IAC valve O-ring. INSTALLATION PROCEDURE NOTE: The IAC valve may be damaged if installed with the cone (pintle) extended more than 28 mm (1-1/8 in). Measure the distance that the valve is extended before installing a new valve. The distance from the idle air control valve motor housing to the end of the idle air control valve pintle Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator - Electronic > Component Information > Diagrams > Page 3292 should be less than 28 mm (1-1/8 in). Manually compress the pintle until the extension is less than 28 mm (1-1/8 in). 1. Install the new IAC valve O-ring. 2. Install the IAC valve in the throttle body. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the IAC valve screws. Tighten Tighten the screws to 3 N.m (27 lb in). 4. Connect the IAC valve electrical connector. 5. The powertrain control module (PCM) will reset the IAC valve whenever the ignition is turned ON, then OFF. Turn ON the ignition for 10 seconds, then OFF for 5 seconds. 6. Start the engine and allow the engine to reach operating temperature. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Specifications Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > Left Side of Instrument Panel Support Left Side Of Instrument Panel Support Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Locations > Left Side of Instrument Panel Support > Page 3298 Lower Center Of Instrument Panel (Without RPO Code 9C1/9C3) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions Information Bus: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3301 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3302 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3303 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3304 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3305 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3306 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3307 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3308 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3309 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3310 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3311 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3312 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3313 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3314 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3315 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3316 Information Bus: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3317 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3318 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3319 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3320 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3321 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3322 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3323 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3324 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3325 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3326 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3327 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3328 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3329 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3330 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3331 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3332 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3333 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3334 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3335 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3336 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3337 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3338 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3339 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3340 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3341 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3342 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3343 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3344 Information Bus: Connector Views Data Link Connector (DLC) Part 1 Data Link Connector (DLC) Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Diagram Information and Instructions > Page 3345 Data Link Connector (DLC) Diagram Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Diagrams > Page 3346 Information Bus: Description and Operation DATA LINK COMMUNICATIONS DESCRIPTION AND OPERATION DATA LINK CONNECTOR (DLC) The DLC is a standardized 16 way connector located below the instrument panel and close to the steering column. Both the connector design and location are dictated by industry wide agreement to follow SAE J1962 standards. All DLCs are required to provide a power supply, hot at all times, to Pin 16. This circuit is used to power the scan tool. All DLCs provide a power ground at Pin 4 and a clean signal ground at Pin 5. The class 2 serial data communications circuit is provided at Pin 2 of the DLC. CLASS 2 SERIAL DATA LINK The class 2 serial data link allows the following modules to communicate and share data with each other: Auxiliary Power Drop Connector - Body Control Module (BCM) - Digital Radio Receiver (U2K or U2L) - Driver Information Center (DIC) - Electronic Brake Control Module (EBCM) - Instrument Panel Cluster (IPC) - OnStar Module (UE1) - Powertrain Control Module (PCM) - Radio - Inflatable Restraint Sensing and Diagnostic Module (SDM) The class 2 serial data link allows a scan tool to communicate with the above modules for diagnostic and testing purposes. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Information Bus: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT - DATA LINK COMMUNICATIONS Begin the diagnosis of the data link communications by performing the Diagnostic System Check for the system in which the customer concern is apparent. The Diagnostic System Check will direct you to the correct procedure within the Data Link Communications section when a communication malfunction is present. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3349 Information Bus: Symptom Related Diagnostic Procedures Scan Tool Does Not Communicate With Class 2 Device SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE CIRCUIT DESCRIPTION Modules connected to the class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. Connecting a scan tool to the DLC allows communication with the modules for diagnostic purposes. Diagnostic trouble codes (DTCs) may be set due to this symptom and during this diagnostic procedure. Complete the diagnostic procedure in order to ensure all the DTCs are diagnosed and cleared from memory. DIAGNOSTIC AIDS - The BCM detects that the ignition is ON and sends the appropriate power mode message to the other modules. The BCM must be connected to the class 2 serial data circuit for many other modules to communicate with the scan tool. - If the class 2 serial data circuit was shorted to ground, U1300 or U1305 will be set as history DTCs. Refer to DTC U1300, U1301, or U1305. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U1300 See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U1301 See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U1305 - If the class 2 serial data circuit was shorted to B+ U1301 or U1305 will be set as history DTCs. Refer to DTC U1300, U1301, or U1305. See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U1300 See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U1301 See: Testing and Inspection/Diagnostic Trouble Code Tests and Associated Procedures/U Code Charts/U1305 TEST DESCRIPTION Steps 1 - 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3350 Steps 4 - 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3351 Steps 8 - 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3352 Steps 12 - 14 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3353 Steps 15 - 17 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3354 Steps 18 - 20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3355 Steps 21 - 23 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3356 Steps 24 - 26 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3357 Steps 27 - 30 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3358 Steps 30 - 35 The numbers below refer to the step numbers on the diagnostic table. 2. A partial malfunction in the class 2 serial data circuit uses a different procedure from a total malfunction of the class 2 serial data circuit. The following modules communicate on the class 2 serial data circuit: Auxiliary Power Drop Connector - BCM - DIC - EBCM - IPC - PCM - Radio - OnStar (UE1) - SDM 3. The following DTC's may be retrieved with a history status, but are not the cause of the present condition: - U1300 - U1301 - U1305 6. A State of Health DTC with a history status may be present along with a U1000 or U1255 having a current status. This indicates that the malfunction occurred when the ignition was ON. 7. Data link connector terminals 2 and 5 provide the connection to the class 2 serial data circuit and the signal ground circuit respectively. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3359 9. A poor connection at the DLC terminal of the star connector would cause this condition but will not set a DTC. 10. An open in the class 2 serial data circuit between the DLC and star connector will prevent the scan tool from communicating with the modules. This condition will not set a DTC. 12. If communication cannot be established the class 2 serial data circuit may be shorted to voltage or ground. The condition may be due to the wiring or due to a malfunction in the BCM. When testing wires for a short, make sure there are no modules connected to the wires being tested. 13. The BCM detects that the ignition is ON and sends the appropriate power mode message to the other modules. Therefore, the BCM must remain connected to the DLC for the other modules to communicate with the scan tool. This test isolates the PCM class 2 serial data circuit. 31. If there are no current DTCs that begin with a "U", the communication malfunction has been repaired. 32. The communication malfunction may have prevented diagnosis of the customer complaint. Scan Tool Does Not Power Up SCAN TOOL DOES NOT POWER UP CIRCUIT DESCRIPTION The data link connector (DLC) is a standardized 16 cavity connector. Connector design and location is dictated by an industry wide standard, and is required to provide the following: Scan tool power battery positive voltage at terminal 16. - Scan tool power ground at terminal 4. - Common signal ground at terminal 5. The scan tool will power up with the ignition OFF. Some modules however, will not communicate unless the ignition is ON and the power mode master (PMM) module sends the appropriate power mode message. TEST DESCRIPTION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3360 Steps 1 - 4 The number below refers to the step number on the diagnostic table. 4. If the battery positive voltage and ground circuits of the DLC are functioning properly. The malfunction must be due to the scan tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Lower Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3364 Rear Middle Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3365 Knock Sensor: Diagrams Knock Sensor (KS) 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3366 Knock Sensor (KS) 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3367 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This KS system uses one or two broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement Knock Sensor: Service and Repair Knock Sensor (KS) 1 Replacement KNOCK SENSOR (KS) 1 REPLACEMENT REMOVAL PROCEDURE CAUTION: Hot engine coolant may cause severe burns. Although the cooling system has been drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of the knock sensor. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Disconnect the knock sensor electrical connector (2). 4. Remove the knock sensor (1). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. 1. Install the knock sensor (1). Tighten Tighten the knock sensor to 19 N.m (14 lb ft). 2. Connect the knock sensor electrical connector (2). 3. Lower the vehicle. 4. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement > Page 3370 Knock Sensor: Service and Repair Knock Sensor (KS) 2 Replacement KNOCK SENSOR (KS) 2 REPLACEMENT REMOVAL PROCEDURE CAUTION: Hot engine coolant may cause severe burns. Although the cooling system has been drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of the knock sensor. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Remove the bolts (2) from the knock sensor heat shield (1). 4. Disconnect the knock sensor electrical connector (3) from the knock sensor. 5. Remove the knock sensor (4). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. 1. Install the knock sensor (4). Tighten Tighten the knock sensor to 19 N.m (14 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement > Page 3371 2. Install the knock sensor heat shield. Tighten Tighten the bolts to 60 N.m (44 lb ft). 3. Connect the knock sensor electrical connector. 4. Lower the vehicle. 5. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 3375 Malfunction Indicator Lamp: Service and Repair SERVICE VEHICLE SOON INDICATOR The "SERVICE VEHICLE SOON" light will come on if there are certain non-emission related vehicle problems. These problems may not be obvious and may affect vehicle performance or durability. The light will come on briefly when the ignition is turned on to show that it is working properly. This light does NOT come on at certain mileage intervals. There is probably a PCM or a BCM Code set that will aid you in diagnosis. RESET PROCEDURE The only way to get the light to go off is to clear the PCM or BCM code(s). This light can NOT be reset or shut off any other way. PCM/BCM codes should be read & repaired before clearing them. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3379 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3380 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3381 Manifold Absolute Pressure (MAP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3382 Manifold Pressure/Vacuum Sensor: Testing and Inspection MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR DIAGNOSIS CIRCUIT DESCRIPTION VIN K The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure which gives an indication of the engine load. The MAP sensor has a 5-volt reference circuit, a low reference circuit, and a signal circuit. The powertrain control module (PCM) supplies 5 volts to the MAP sensor on the 5-volt reference circuit and provides a ground on the low reference circuit. The MAP sensor provides a signal to the PCM on the MAP sensor signal circuit, which is relative to the pressure changes in the manifold. With low MAP, such as during idle or deceleration, the PCM should detect a low MAP sensor signal voltage. With high MAP, such as ignition ON, engine OFF, or wide open throttle (WOT), the PCM should detect a high MAP sensor signal voltage. This MAP sensor will indicate pressure between 10-104 kPa. The MAP sensor is also used in order to calculate the barometric pressure (BARO) when the ignition switch is turned ON, with the engine OFF. The BARO reading may also be updated whenever the engine is operated at WOT. The PCM monitors the MAP sensor signal for voltage outside of the normal range. If the PCM detects a MAP sensor signal voltage that is excessively low, DTC P0107 sets. If the PCM detects a MAP sensor signal voltage that is excessively high, DTC P0108 sets. TEST DESCRIPTION Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3383 Steps 4-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3384 Steps 6-10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3385 Steps 11-14 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3386 Steps 15-16 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3387 Steps 17-22 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3388 Steps 23-29 The number below refers to the step number on the diagnostic table. 4. This step tests the MAP sensor's ability to correctly indicate BARO. 12. The measurement noted in this step will be used in subsequent steps if the measurement does not exceed the specified value. 15. This step calculates the resistance in the 5-volt reference circuit. 16. This step calculates the resistance in the low reference circuit. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3389 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT On the L36, the manifold absolute pressure (MAP) sensor is mounted to the positive crankcase ventilation (PCV) valve cover. Removal Procedure 1. Remove the fuel injector sight shield. 2. Disconnect the MAP sensor electrical connector. 3. Carefully release the locking tabs holding the MAP (1) sensor to the PCV valve cover (2) just enough to remove the MAP sensor. 4. Pull the MAP sensor straight out of PCV valve cover. Installation Procedure 1. Ensure that the seal is installed on the MAP sensor and that the seal is not damaged. 2. Position and install the MAP sensor (1) to the PCV valve cover (2). Ensure that the locking tabs engage to hold the MAP sensor to the PCV valve cover. 3. Connect the MAP sensor electrical connector. 4. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 3393 Lower Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 3394 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 3395 Engine Oil Level Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the engine oil pressure switch electrical connector. 3. Remove the oil pressure switch. Installation Procedure Notice; Refer to Fastener Notice in Service Precautions. 1. Install the engine oil pressure switch. - Tighten the switch to 16 Nm (12 ft. lbs.). 2. Connect the engine oil pressure switch electrical connector. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations Upper Left Rear Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3402 Oxygen Sensor: Diagrams Heated Oxygen Sensor (HO2S) Sensor 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3403 Heated Oxygen Sensor (HO2S) Sensor 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) 1 Replacement Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 1 Replacement HEATED OXYGEN SENSOR (HO2S) 1 REPLACEMENT TOOLS REQUIRED J 39194 Oxygen Sensor Wrench NOTE: The Heated Oxygen Sensor (HO2S) and the Oxygen Sensor use a permanently attached pigtail and connector. Do not remove this pigtail from the Heated Oxygen Sensor. Damage or the removal of the pigtail or the connector could affect the proper operation of the sensor. Take care when handling the HO2S and the O2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Also avoid using cleaning solvents of any type. Do not drop the HO2S or the O2S. Do not roughly handle the HO2S or the O2S. Removal Procedure NOTE: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. 1. Remove the fuel injector sight shield. 2. Remove the heated oxygen sensor (HO2S) electrical CPA retainer. 3. Disconnect the HO2S wiring harness connector (3) from the HO2S electrical connector (4). 4. Remove the HO2S electrical connector (4) from the fuel injector sight shield bracket (1). IMPORTANT: Remove the oxygen sensor with the engine temperature above 48°C (120°F). Otherwise the oxygen sensors may be difficult to remove. 5. Use the J 39194 to remove the HO2S (2). Installation Procedure NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: A special anti-seize compound is used on the oxygen sensor (1) threads. New service sensors should already have the compound applied to the threads. Coat the threads of a reused sensor with anti-seize compound P/N 12377953 or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) 1 Replacement > Page 3406 1. Install the rear oxygen sensor in the right exhaust manifold. Tighten Use the J 39194 to tighten the HO2S to 41 N.m (30 lb ft). 2. Connect the HO2S electrical connector (4) to the wiring harness connector (3). 3. Install the HO2S electrical connector (4) to the fuel injector sight shield bracket (1). 4. Install the HO2S electrical CPA retainer. 5. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) 1 Replacement > Page 3407 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 2 Replacement HEATED OXYGEN SENSOR (HO2S) 2 REPLACEMENT TOOLS REQUIRED J 39194 Oxygen Sensor Wrench NOTE: The Heated Oxygen Sensor (HO2S) and the Oxygen Sensor use a permanently attached pigtail and connector. Do not remove this pigtail from the Heated Oxygen Sensor. Damage or the removal of the pigtail or the connector could affect the proper operation of the sensor. Take care when handling the HO2S and the O2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Also avoid using cleaning solvents of any type. Do not drop the HO2S or the O2S. Do not roughly handle the HO2S or the O2S. Removal Procedure NOTE: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the HO2S electrical connector retaining tab (1) from the HO2S electrical connector (2). 3. Disconnect the HO2S electrical connector from the HO2S electrical connector (2). 4. Use the J 39194 to remove the HO2S from the exhaust pipe. Installation Procedure NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: A special anti-seize compound is used on the oxygen sensor threads. New service sensors should already have the compound applied to the threads. Coat the threads of a reused sensor with anti-seize compound P/N 12377953 or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) 1 Replacement > Page 3408 1. Install the oxygen sensor (4) to the exhaust pipe. Tighten Use the J 39194 to tighten the oxygen sensor to 41 N.m (30 lb ft). 2. Connect the HO2S connector (4) to the HO2S electrical connector (2). 3. Install the retaining tab (1) to the HO2S electrical connector. 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: Customer Interest BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 3418 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: All Technical Service Bulletins BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 3424 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception Antenna Control Module: All Technical Service Bulletins Audio System - Static/Poor Radio Reception Bulletin No.: 05-08-44-008A Date: June 17, 2005 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Static, Poor and/or No AM/FM Radio Reception In Police Package Equipped Vehicles (Replace Radio Antenna Module) Models: 2004-2005 Chevrolet Impala Built After VIN Breakpoint 49302036 with Police Package (RPO 9C1) Supercede: This bulletin is being revised to include Diagnostic and Repair Information, remove an RPO code and include a VIN breakpoint. Please discard Corporate Bulletin Number 05-08-44-008 (Section 08 - Body and Accessories). Condition Some customers may comment that certain police package vehicles equipped with radio communication equipment may experience poor AM/FM radio reception, no radio reception and/or static through the radio system. Cause Police package vehicles radio communication equipment may overload the radio AM/FM radio antenna module. Diagnosis To ensure the radio antenna module is the cause of the poor reception, refer to Radio Poor Reception (SI Document ID # 782713). Correction If diagnosis leads to a suspect radio antenna module, replace the Radio Antenna Module. Refer to Antenna Module Replacement (SI Document ID # 1515377). Dealer Action Contact customers that were told they would be notified when this repair became available. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception > Page 3434 Parts Parts will be available for dealer ordering on June 20, 2005. Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception > Page 3440 Parts Parts will be available for dealer ordering on June 20, 2005. Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 3441 Behind Left Side Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 Body Control Module: Diagrams Body Control Module (BCM) C1 Body Control Module, C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3444 Body Control Module, C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3445 Body Control Module, C1 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3446 Body Control Module: Diagrams Body Control Module (BCM) C2 Body Control Module, C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3447 Body Control Module, C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3448 Body Control Module: Diagrams Body Control Module (BCM) C3 Body Control Module, C3 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 3449 Body Control Module, C3 Part 2 Body Control Module, C3 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Page 3450 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. The BCM has five basic modes (disarmed, standby, delayed, armed, and alarm) for operating the CTD system. The different modes are described below. 1. The BCM has the CTD system in a disarmed mode until the following conditions are detected: - Ignition key turned to the OFF position. - Any door open. - Doors locked by either the power door lock switch or the LOCK button on the transmitter. 2. The BCM enters the standby mode when the above conditions are detected. In standby mode, the BCM commands the SECURITY indicator to flash. If all the doors are closed and the LOCK button on the transmitter is used, the BCM enters the delayed mode. 3. When the last door is closed, the BCM enters the delayed mode for 30 seconds. In delayed mode the BCM commands the SECURITY indicator to illuminate ON steady. 4. After 30 seconds, the BCM enters the armed mode. Any forced entry activates the alarm mode. 5. When the BCM detects a forced entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active.The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. The body control module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(TM) data from the Passlock(TM) sensor. If the Passlock(TM) data is correct, the BCM will send a class 2 message to the PCM to enable the fuel injectors and crank relay. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(TM) data, the VTD system will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors and crank relay for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(TM) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable and crank relay enable signal to the PCM. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION During body control module (BCM) related service, the procedures below are designated to set-up the BCM correctly. Before you start, read these procedures carefully and completely. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: The BCM will not function properly if the Setup New BCM procedure is not performed. - Make sure the battery is fully charged before performing the setup procedure. - Make sure all disconnected devices and connectors have been reconnected - Perform the Theft Deterrent Re-learn procedure after successfully finishing the Setup New BCM procedure. Refer to Programming Theft Deterrent System Components in Theft Deterrent. If the Theft Deterrent Re-learn procedure is not performed after a BCM replacement, the following conditions may occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. 1. Connect a scan tool to the data link connector (DLC). 2. Turn the ignition switch ON. 3. Select Diagnostics and input all of the required data when prompted by the scan tool. 4. Select BODY CONTROL MODULE. 5. Select SPECIAL FUNCTIONS. 6. Select New VIN and input all required data. 7. Exit back to the SPECIAL FUNCTIONS menu. 8. Select BCM REPROGRAMMING. 9. The scan tool will display DO YOU WANT TO SETUP A BODY CONTROL MODULE? At the prompt, select SETUP BCM hotspot on the scan tool. 10. The scan tool will display: NOW SETTING UP THE NEW BODY CONTROL MODULE. 11. When the BCM has been setup successfully, the scan tool will display: BODY CONTROL MODULE SETUP IS COMPLETE. 12. Exit back to the SPECIAL FUNCTIONS menu. 13. Select Point of Sale in this menu. 14. Input all of the required data when prompted by the scan tool. 15. Exit back to the SET OPTIONS menu. 16. Select Option Configuration. 17. Input all of the required data when prompted by the scan tool. 18. When the BCM, VIN, Point of Sale and Option Configuration have been entered, proceed with the Theft Deterrent Re-learn procedure. 19. If the scan tool displays UNABLE TO PROGRAM BCM. BCM IS SECURED, then the BCM must be replaced and this procedure must be repeated on a new BCM. NOTE: After the above procedure has been completed, personalization of the BCM defaults to a default setting. Inform the customer that the personalization settings must be set again. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 3453 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: You must perform the new body control module (BCM) setup when replacing the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 1. Disconnect the battery ground (negative) cable. 2. Remove the left instrument panel insulator. 3. Disconnect the BCM electrical connectors (2,3,4). 4. Remove the BCM (1). INSTALLATION PROCEDURE 1. Install the body control module (BCM) (1). 2. Connect the BCM electrical connectors (2,3,4). 3. Install the left instrument panel insulator. 4. Connect the battery ground (negative) cable. 5. Perform the new BCM setup. Refer to Body Control Module (BCM) Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage Engine Control Module: Technical Service Bulletins Engine Controls - Aftermarket Accessory Usage INFORMATION Bulletin No.: 04-06-04-054B Date: November 18, 2010 Subject: Info - Non-GM Parts and Accessories (Aftermarket) Models: 2011 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add model years and update to the new U.S. Fixed Operation Manager (FOM) and Canada Warranty Manager (WM) names. Please discard Corporate Bulletin Number 04-06-04-054A (Section 06 - Engine/Propulsion System). The recent rise and expansion of companies selling non-GM parts and accessories has made it necessary to issue this reminder to dealers regarding GM's policy on the use and installation of these aftermarket components. When a dealer is performing a repair under the New Vehicle Limited Warranty, they are required to use only genuine GM or GM-approved parts and accessories. This applies to all warranty repairs, special policy repairs or any repairs paid for by GM. Parts and accessories advertised as being "the same" as parts manufactured by GM, but not sold through GM, do not qualify for use in warranty repairs, special policy repairs or any repairs paid for by GM. During a warranty repair, if a GM original equipment part is not available through GM Customer Care and Aftersales (GM CC&A;), ACDelco(R) distributors, other GM dealers or approved sources, the dealer is to obtain comparable, non-GM parts and clearly indicate, in detail, on the repair order the circumstances surrounding why non-GM parts were used. The dealer must give customers written notice, prior to the sale or service, that such parts or accessories are not marketed or warranted by General Motors. It should also be noted that dealers modifying new vehicles and installing equipment, parts and accessories obtained from sources not authorized by GM are responsible for complying with the National Traffic and Motor Vehicle Safety Act. Certain non-approved parts or assemblies, installed by the dealer or its agent not authorized by GM, may result in a change to the vehicle's design characteristics and may affect the vehicle's ability to conform to federal law. Dealers must fully understand that non-GM approved parts may not have been validated, tested or certified for use. This puts the dealer at risk for potential liability in the event of a part or vehicle failure. If a GM part failure occurs as the result of the installation or use of a non-GM approved part, the warranty will not be honored. A good example of non-authorized modification of vehicles is the result of an ever increasing supply of aftermarket devices available to the customer, which claim to increase the horsepower and torque of the Duramax(TM) Diesel Engines. These include the addition of, but are not limited to one or more of the following modifications: - Propane injection - Nitrous oxide injection - Additional modules (black boxes) that connect to the vehicle wiring systems - Revised engine calibrations downloaded for the engine control module - Calibration modules which connect to the vehicle diagnostic connector - Modification to the engine turbocharger waste gate Although the installation of these devices, or modification of vehicle components, can increase engine horsepower and torque, they may also negatively affect the engine emissions, reliability and/or durability. In addition, other powertrain components, such as transmissions, universal joints, drive shafts, and front/rear axle components, can be stressed beyond design safety limits by the installation of these devices. General Motors does not support or endorse the use of devices or modifications that, when installed, increase the engine horsepower and torque. It is because of these unknown stresses, and the potential to alter reliability, durability and emissions performance, that GM has adopted a policy that prevents any UNAUTHORIZED dealer warranty claim submissions to any remaining warranty coverage, to the powertrain and driveline components whenever the presence of a non-GM (aftermarket) calibration is confirmed - even if the non-GM control module calibration is subsequently removed. Refer to the latest version of Bulletin 09-06-04-026 (V8 Gas Engines) or 06-06-01-007 (Duramax(TM) Diesel Engines) for more information on dealer requirements for calibration verification. These same policies apply as they relate to the use of non-GM accessories. Damage or failure from the use or installation of a non-GM accessory will not be covered under warranty. Failure resulting from the alteration or modification of the vehicle, including the cutting, welding or disconnecting of the vehicle's original equipment parts and components will void the warranty. Additionally, dealers will NOT be reimbursed or compensated by GM in the event of any legal inquiry at either the local, state or federal level that Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Engine Controls - Aftermarket Accessory Usage > Page 3458 results from the alteration or modification of a vehicle using non-GM approved parts or accessories. Dealers should be especially cautious of accessory companies that claim the installation of their product will not void the factory warranty. Many times these companies have even given direction on how to quickly disassemble the accessory in an attempt to preclude the manufacturer from finding out that is has been installed. Any suspect repairs should be reviewed by the Fixed Operations Manager (FOM), and in Canada by the Warranty Manager (WM) for appropriate repair direction. If it is decided that a goodwill repair is to be made on the vehicle, even with the installation of such non-GM approved components, the customer is to be made aware of General Motors position on this issue and is to sign the appropriate goodwill documentation required by General Motors. It is imperative for dealers to understand that by installing such devices, they are jeopardizing not only the warranty coverage, but also the performance and reliability of the customer's vehicle. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3459 Left Front Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 Engine Control Module: Diagrams Powertrain Control Module, C1 Powertrain Control Module, C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 3462 Powertrain Control Module, C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 3463 Powertrain Control Module, C1 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 3464 Powertrain Control Module, C1 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 3465 Engine Control Module: Diagrams Powertrain Control Module, C2 Powertrain Control Module, C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 3466 Powertrain Control Module, C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 3467 Powertrain Control Module, C2 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Powertrain Control Module, C1 > Page 3468 Powertrain Control Module, C2 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module Engine Control Module: Description and Operation Powertrain Control Module POWERTRAIN CONTROL MODULE (PCM) DESCRIPTION The PCM communicates with the BCM over the Class 2 serial data line. When the BCM determines an incorrect password, it sends a Class 2 serial data password to the PCM in order to disable the crank relay and fuel injection system. If the BCM receives the expected voltage from the Passlock(TM) sensor, the BCM sends a class 2 serial data password to the PCM in order to enable the crank relay and fuel injection system. The PCM then allows the vehicle to start normally. POWERTRAIN The powertrain has electronic controls to reduce exhaust emissions while maintaining excellent driveability and fuel economy. The powertrain control module (PCM) is the control center of this system. The PCM monitors numerous engine and vehicle functions. The PCM constantly looks at the information from various sensors and other inputs, and controls the systems that affect vehicle performance and emissions. The PCM also performs the diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. Review the components and wiring diagrams in order to determine which systems are controlled by the PCM. The following are some of the functions that the PCM controls: The engine fueling - The ignition control (IC) - The knock sensor (KS) system - The evaporative emissions (EVAP) system - The secondary air injection (AIR) system (if equipped) - The exhaust gas recirculation (EGR) system - The automatic transmission functions - The generator - The A/C clutch control - The cooling fan control POWERTRAIN CONTROL MODULE FUNCTION The PCM constantly looks at the information from various sensors and other inputs and controls systems that affect vehicle performance and emissions. The PCM also performs diagnostic tests on various parts of the system. The PCM can recognize operational problems and alert the driver via the malfunction indicator lamp (MIL). When the PCM detects a malfunction, the PCM stores a diagnostic trouble code (DTC). The problem area is identified by the particular DTC that is set. The control module supplies a buffered voltage to various sensors and switches. The input and output devices in the PCM include analog-to-digital converters, signal buffers, counters, and output drivers. The output drivers are electronic switches that complete a ground or voltage circuit when turned on. Most PCM controlled components are operated via output drivers. The PCM monitors these driver circuits for proper operation and, in most cases, can set a DTC corresponding to the controlled device if a problem is detected. MALFUNCTION INDICATOR LAMP (MIL) OPERATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module > Page 3471 The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. TRIP A trip is an interval of time during which the diagnostic test runs. A trip may consist of only a key cycle to power up the PCM, allow the diagnostic to run, then cycle the key off to power down the PCM. A trip may also involve a PCM power up, meeting specific conditions to run the diagnostic test, then powering down the PCM. The definition of a trip depends upon the diagnostic. Some diagnostic tests run only once per trip (i.e., catalyst monitor) while other tests run continuously during each trip (i.e. misfire). WARM-UP CYCLE The PCM uses warm-up cycles to run some diagnostics and to clear any diagnostic trouble codes (DTCs). A warm-up cycle occurs when the engine coolant temperature increases 22°C (40°F) from the start-up temperature. The engine coolant must also achieve a minimum temperature of 71°C (160 °F). The PCM counts the number of warm-up cycles in order to clear the malfunction indicator lamp (MIL). The PCM will clear the DTCs when 40 consecutive warm-up cycles occur without a malfunction. DIAGNOSTIC TROUBLE CODES (DTCS) The PCM is programmed with test routines that test the operation of the various systems the PCM controls. Some tests monitor internal PCM functions. Many tests are run continuously. Other tests run only under specific conditions, referred to as Conditions for Running the DTC. When the vehicle is operating within the conditions for running a particular test, the PCM monitors certain parameters and determines if the values are within an expected range. The parameters and values considered outside the range of normal operation are listed as Conditions for Setting the DTC. When the Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module > Page 3472 Conditions for Setting the DTC occur, the PCM executes the Action Taken When the DTC Sets. Some DTCs alert the driver via the MIL or a message. Other DTCs do not trigger a driver warning, but are stored in memory. The PCM also saves data and input parameters when most DTCs are set. This data is stored in the Freeze Frame and/or Failure Records. The DTCs are categorized by type. The DTC type is determined by the MIL operation and the manner in which the fault data is stored when a particular DTC fails. In some cases there may be exceptions to this structure. Therefore, when diagnosing the system it is important to read the Action Taken When the DTC Sets and the Conditions for Clearing the DTC in the supporting text. There are different types of DTCs and different actions taken when the DTCs set. Refer to Diagnostic Trouble Code (DTC) Type Definitions for a description of the general characteristics of each DTC type. DTC STATUS When the scan tool displays a DTC, the status of the DTC is also displayed. The following DTC statuses are indicated only when they apply to the DTC that is set. Fail This Ign. (Fail This Ignition): Indicates that this DTC failed during the present ignition cycle. Last Test Fail: Indicates that this DTC failed the last time the test ran. The last test may have run during a previous ignition cycle if an A or B type DTC is displayed. For type C DTCs, the last failure must have occurred during the current ignition cycle to appear as Last Test Fail. MIL Request: Indicates that this DTC is currently requesting the MIL. This selection will report type B DTCs only when they have requested the MIL (failed twice). Test Fail SCC (Test Failed Since Code Clear): Indicates that this DTC that has reported a failure since the last time DTCs were cleared. History: Indicates that the DTC is stored in the PCM History memory. Type B DTCs will not appear in History until they have requested the MIL (failed twice). History will be displayed for all type A DTCs and type B DTCs (which have requested the MIL) that have failed within the last 40 warm-up cycles. Type C DTCs that have failed within the last 40 warm-up cycles will also appear in History. Not Run SCC (Not Run Since Code Clear): DTCs will be listed in this category if the diagnostic has not run since DTCs were last cleared. This status is not included with the DTC display since the DTC can not be set if the diagnostic has not run. This information is displayed when DTC Info is requested using the scan tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Powertrain Control Module > Page 3473 Engine Control Module: Description and Operation Electronic Ignition (EI) System POWERTRAIN CONTROL MODULE (PCM) The PCM maintains proper spark and fuel injection timing for all driving conditions. Ignition control (IC) spark timing is the method the PCM uses to control spark advance. To provide optimum driveability and emissions, the PCM monitors input signals from the following components to calculate ignition spark timing: The ignition control module (ICM) - The throttle position (TP) sensor - The engine coolant temperature (ECT) sensor - The mass air flow (MAF) sensor - The intake air temperature (IAT) sensor - The vehicle speed sensor (VSS) - The transmission gear position or range information sensors - The engine knock sensors (KS) The following describes the PCM to ICM circuits: Low resolution engine speed signal-3 X reference-PCM input-from the ICM. The 3X reference signal is produced by the ICM. The PCM uses this signal to calculate engine RPM and crankshaft position above 1,200 RPM. The PCM also uses the pulses on this circuit to initiate fuel injector operation. The PCM compares the number of 3X pulses to the number of 18X and cam pulses. If the number of 3X pulses are incorrect while the engine is cranking or running, the PCM will set a DTC. The engine will continue to start and run normally using the 18X reference signal. - Medium resolution engine speed signal-18 X reference-PCM input-from the ICM. The 18 X reference signal is used to accurately control spark timing at low RPM and allow ignition control (IC) operation during cranking. The ICM calculates the 18X reference signal by filtering the CKP sensor 18X pulses when the engine is running and the CKP sync pulses are being received. Below 1,200 RPM, the PCM is monitoring the 18X reference signal and using the 18X signal as the reference for ignition timing advance. The PCM compares the number of 18X pulses to the number of 3X and cam pulses. If the number of 18X pulses are incorrect while the engine is cranking or running, the PCM will set a DTC. The engine will continue to start and run normally using the 3X reference signal. - Camshaft position-PCM input-from the ICM. The PCM uses this signal to determine the position of the cylinder #1 piston during the pistons power stroke. This signal is used by the PCM to calculate true sequential fuel injection (SFI) mode of operation. The PCM compares the number of CAM pulses to the number of 18 X and 3 X reference pulses. If the number of 18 X and 3 X reference pulses occurring between CAM pulses is incorrect, or if no CAM pulses are received while the engine is running, the PCM will set a DTC. If the CAM signal is lost while the engine is running the fuel injection system will shift to a calculated sequential fuel injection mode based on the last CAM pulse, and the engine will continue to run. The engine can be re-started and will run in the calculated sequential mode as long as the condition is present with a 1 in 6 chance of being correct. - Low reference-PCM input-this is a ground circuit for the digital RPM counter inside the PCM, but the wire is connected to engine ground only through the ICM. This circuit assures there is no ground drop between the PCM and ICM. - IC timing signal-PCM output-to the ICM. The ICM controls spark timing while the engine is cranking, this is called bypass mode. Once the PCM receives 3 X reference signals from the ICM, the PCM applies 5 volts to the IC timing signal circuit allowing the ICM to switch spark advance to PCM control. - IC timing control-PCM output-to the ICM. The IC output circuitry of the PCM sends out timing signals to the ICM on this circuit. When in the Bypass Mode, the ICM grounds these signals. When in the IC Mode, the signals are sent to the ICM to control spark timing. - Default mode due to a system failure The other mode is the IC mode during which the PCM is receiving the 18X and the 3X reference pulses from the CKP sensor and is supplying 5 volts to the IC timing signal circuit. This allow the PCM to accurately control spark timing for all driving conditions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3474 Engine Control Module: Service and Repair POWERTRAIN CONTROL MODULE (PCM) REPLACEMENT Service of the powertrain control module (PCM) should normally consist of either replacement of the PCM or electrically erasable programmable read only memory (EEPROM) programming. If the diagnostic procedures call for PCM replacement, inspect the PCM first to see if the replacement is the correct part. If the PCM is faulty, remove the PCM and install the new service PCM. The new service PCM will not be programmed. You must program the new PCM. DTC P0602 indicates the EEPROM is not programmed or has malfunctioned. NOTE: - Do not touch the connector pins or soldered components on the circuit board in order to prevent possible electrostatic discharge (ESD) damage to the PCM. - Turn the ignition OFF when installing or removing the PCM connectors and disconnecting or reconnecting the power to the PCM (battery cable, PCM pigtail, PCM fuse, jumper cables, etc.) in order to prevent internal PCM damage. Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the left front inner fender brace. 3. Remove the air cleaner intake duct. 4. Remove the air cleaner housing cover screws (2). 5. Remove the air cleaner housing cover (1). 6. Without disconnecting the PCM electrical connectors, remove the PCM and the wiring harness from the air cleaner housing assembly (3). 7. Disconnect the PCM electrical connectors and remove the PCM. Installation Procedure NOTE: Refer to Fastener Notice in Service Precautions. 1. Install the PCM to the PCM electrical connectors. Tighten Tighten the connectors to 8 N.m (71 lb in). 2. Install the PCM and the wiring harness to the air cleaner housing assembly (3). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3475 3. Install the air cleaner housing cover (1). 4. Install the air cleaner housing cover screws (2). Tighten Tighten the screws to 4 N.m (35 lb in). 5. Install the air cleaner intake duct. 6. Install the left front inner fender brace. 7. Connect the negative battery cable. 8. The new PCM must be programmed. Refer to Service Programming System (SPS) in Programming. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations Left Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3480 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3481 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3482 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3483 Mass Air Flow (MAF) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3484 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. IMPORTANT: The mass air flow (MAF) sensor is attached to the throttle body assembly. 2. Disconnect the MAF sensor electrical connector (8). 3. Remove the MAF sensor screws (9). 4. Remove the MAF sensor (1). INSTALLATION PROCEDURE 1. Install the MAF sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF sensor screws (9). Tighten Tighten the screws to 3 N.m (27 lb in). 3. Connect the MAF sensor electrical connector (8). 4. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3488 Right Middle Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3489 Camshaft Position (CMP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3490 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The camshaft position (CMP) sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor does not directly affect the operation of the ignition system. The CMP sensor information is used by the powertrain control module (PCM) to determine the position of the valve train relative to the CKP. By monitoring the CMP and CKP signals the PCM can accurately time the operation of the fuel injectors. The CMP sensor shares 12-volt and low reference circuits with the CKP sensor. The CMP signal circuit is input to the ICM. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3491 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the coolant recovery reservoir. 2. Remove the drive belt. 3. Disconnect the electrical connector (2) from the camshaft position sensor (1). 4. Remove the camshaft position sensor bolt. 5. Remove the camshaft position sensor from the engine front cover. INSTALLATION PROCEDURE 1. Install the camshaft position sensor to the engine front cover. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Locations > Page 3492 2. Install the camshaft position sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 3. Connect the electrical connector (2) to the camshaft position sensor (1). 4. Install the drive belt. 5. Install the coolant recovery reservoir. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3496 Engine Coolant Temperature (ECT) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3497 Coolant Temperature Sensor/Switch (For Computer): Service and Repair ENGINE COOLANT TEMPERATURE (ECT) SENSOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. 1. Partially drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the thermostat housing. 3. Disconnect the ECT sensor electrical connector. 4. Remove the ECT sensor. INSTALLATION PROCEDURE NOTE: Use care when handling the coolant sensor. Damage to the coolant sensor will affect the operation of the fuel control system. - Replacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage. 1. Coat the threads with sealer GM P/N 12346004 (Canadian P/N 10953480) or equivalent. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ECT sensor. Tighten Tighten the ECT sensor to 20 N.m (15 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Locations > Page 3498 3. Connect the ECT sensor electrical connector. 4. Install the thermostat housing. 5. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3502 Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3503 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3504 Camshaft Position (CKP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3505 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSORS The crankshaft position (CKP) sensor has a 4-wire harness connector that plugs into the CKP sensor and connects to the ignition control module (ICM). The CKP sensor contains 2 hall-effect switches in 1 housing, and shares a magnet between the switches. The magnet and each hall-effect switch are separated by an air gap. A hall-effect switch is a solid state switching device that produces a digital ON/OFF pulse when a rotating element passes the sensor pick-up and interrupts the magnetic field of the sensor. The rotating element is called an interrupter ring or blade. There are two interrupter rings built into the crankshaft balancer. The outer ring and the outer switch provide the ICM with 18X signals or 18 identical pulses per crankshaft revolution. The inner ring and the inner switch provide the ICM with 3 pulses per revolution, each 1 of different duration. This is called the sync pulse. Each sync pulse represents a pair of companion cylinders. The ICM supplies a 12-volt and a low reference circuit to the CKP sensor, which is also shared by the camshaft position (CMP) sensor. The 18X reference pulses are passed from the CKP sensor to the ICM on the CKP sensor 1 signal circuit. The sync pulses are passed from the CKP sensor to the ICM on the CKP sensor 2 signal circuit. The ICM uses the 18X and sync pulses to determine the crankshaft position by counting how many ON-OFF 18X pulses occur during a sync pulse. With this dual interrupter ring arrangement the ICM can identify the correct pair of cylinders to fire within as little as 120 degrees of crankshaft rotation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3506 Crankshaft Position Sensor: Testing and Inspection CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The ignition control module (ICM) monitors the crankshaft position (CKP) sensor sync signal when the engine is cranking. The CKP sync signal is passed from the CKP sensor to the ICM on the CKP sensor 2 signal circuit. The CKP sync signal is used to determine the correct cylinder pair and initiate the ignition coil firing sequence. The 18X reference pulses are passed from the CKP sensor to the ICM on the CKP sensor 1 signal circuit. The 18X reference pulses are used for fuel injection and ignition control. After the ICM receives both signals, the ICM passes the 18X and 3X reference signals to the powertrain control module (PCM). The camshaft position sensor and the CKP sensor share a 12-volt reference and a low reference circuit. The CKP sensor consists of the following circuits: A 12-volt reference circuit - A low reference circuit - A CKP sensor 1 signal circuit - A CKP sensor 2 signal circuit TEST Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3507 Steps 4-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3508 Steps 8-14 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3509 Steps 15-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3510 Steps 21-26 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3511 Steps 27-28 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations > Page 3512 Steps 29-31 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 4.1. Accelerate to wide open throttle (WOT). 4.2. Release throttle when fuel cut-off occurs. 4.3. Observe fuel cut-off specification for applicable engine. 4.4. Engine should not accelerate beyond calibrated RPM value. 4.5. Release throttle immediately if value is exceeded. 4.6. Block drive wheels. 4.7. Set parking brake. 4.8. DO NOT apply brake pedal. 4.9. Cycle ignition from OFF to ON. 4.10. Apply and hold brake pedal. 4.11. Start and idle engine. 4.12. Turn A/C OFF. 4.13. Vehicle must remain in Park or Neutral. 4.14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure.The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - Crankshaft position (CKP) sensors activity - If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity - If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool and perform the following: IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 5.1. Accelerate to WOT. 5.2. Release when fuel cut-off occurs. 5.3. Test in progress. 6. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 . If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC. 7. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set Engine replacement - PCM replacement - A harmonic balancer replacement - Crankshaft replacement - CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3515 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the right splash shield cover. 4. Remove the crankshaft balancer. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the CKP sensor shield (1). 7. Remove the CKP sensor bolts. 8. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 3516 1. Position the CKP sensor to the block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolts. Tighten Tighten the bolts to 30 N.m (22 lb ft) 3. Install the CKP sensor shield (1). 4. Connect the CKP sensor electrical connector. 5. Install the crankshaft balancer. 6. Install the right splash shield cover. 7. Lower the vehicle. 8. Connect the negative battery cable. 9. Perform the Crankshaft Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations Fuel Level Sensor: Locations Fuel Pump And Sender Assembly Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3520 Fuel Level Sensor: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Locations > Page 3521 Fuel Level Sensor: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Remove the fuel sender assembly. 2. Disconnect the fuel level sensor electrical connector. 3. Remove the fuel level sensor (5) from the fuel sender assembly. INSTALLATION PROCEDURE 1. Install the fuel level sensor (5) to the fuel sender assembly. 2. Connect the fuel level sensor electrical connector. 3. Install the fuel sender assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations Fuel Tank Pressure Sensor: Locations Fuel Pump And Sender Assembly Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3525 Fuel Tank Pressure (FTP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3526 Fuel Tank Pressure Sensor: Description and Operation FUEL TANK PRESSURE SENSOR The FTP sensor measures the difference between the pressure or vacuum in the fuel tank and outside air pressure. The control module provides a 5-volt reference and a ground to the FTP sensor. The FTP sensor provides a signal voltage back to the control module that can vary between 0.1-4.9 volts. As FTP increases, FTP sensor voltage decreases, high pressure = low voltage. As FTP decreases, FTP voltage increases, low pressure or vacuum = high voltage. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Tank Pressure Sensor > Component Information > Locations > Page 3527 Fuel Tank Pressure Sensor: Service and Repair FUEL TANK PRESSURE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel tank pressure sensor (7) from the fuel sender assembly (1). 2. Disconnect the negative battery cable. 3. Remove the fuel sender assembly. INSTALLATION PROCEDURE 1. Install the new fuel tank pressure sensor (7) to the fuel sender assembly (1). 2. Install the fuel sender assembly. 3. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Locations Intake Air Temperature (IAT) Sensor: Locations Intake Air Temperature Sensor (IAT) is in the air induction tube. 3. Intake Air Temperature (IAT) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions Intake Air Temperature (IAT) Sensor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3533 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3534 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3535 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3536 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3537 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3538 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3539 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3540 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3541 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3542 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3543 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3544 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3545 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3546 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3547 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3548 Intake Air Temperature (IAT) Sensor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3549 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3550 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3551 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3552 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3553 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3554 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3555 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3556 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3557 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3558 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3559 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3560 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3561 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3562 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3563 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3564 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3565 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3566 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3567 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3568 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3569 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3570 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3571 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3572 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3573 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3574 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3575 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Diagram Information and Instructions > Page 3576 Intake Air Temperature (IAT) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature (IAT) Sensor <--> [Intake Air Temperature Sensor] > Component Information > Diagrams > Page 3577 Intake Air Temperature (IAT) Sensor: Service and Repair INTAKE AIR TEMPERATURE (IAT) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector. 2. Remove the IAT sensor (3) with a twisting and pulling motion. INSTALLATION PROCEDURE 1. Install the IAT sensor (3). 2. Connect the IAT sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Lower Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3581 Rear Middle Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3582 Knock Sensor: Diagrams Knock Sensor (KS) 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3583 Knock Sensor (KS) 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3584 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This KS system uses one or two broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement Knock Sensor: Service and Repair Knock Sensor (KS) 1 Replacement KNOCK SENSOR (KS) 1 REPLACEMENT REMOVAL PROCEDURE CAUTION: Hot engine coolant may cause severe burns. Although the cooling system has been drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of the knock sensor. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Disconnect the knock sensor electrical connector (2). 4. Remove the knock sensor (1). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. 1. Install the knock sensor (1). Tighten Tighten the knock sensor to 19 N.m (14 lb ft). 2. Connect the knock sensor electrical connector (2). 3. Lower the vehicle. 4. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement > Page 3587 Knock Sensor: Service and Repair Knock Sensor (KS) 2 Replacement KNOCK SENSOR (KS) 2 REPLACEMENT REMOVAL PROCEDURE CAUTION: Hot engine coolant may cause severe burns. Although the cooling system has been drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of the knock sensor. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Remove the bolts (2) from the knock sensor heat shield (1). 4. Disconnect the knock sensor electrical connector (3) from the knock sensor. 5. Remove the knock sensor (4). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. 1. Install the knock sensor (4). Tighten Tighten the knock sensor to 19 N.m (14 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement > Page 3588 2. Install the knock sensor heat shield. Tighten Tighten the bolts to 60 N.m (44 lb ft). 3. Connect the knock sensor electrical connector. 4. Lower the vehicle. 5. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations Manifold Pressure/Vacuum Sensor: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3592 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3593 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3594 Manifold Absolute Pressure (MAP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3595 Manifold Pressure/Vacuum Sensor: Testing and Inspection MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR DIAGNOSIS CIRCUIT DESCRIPTION VIN K The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure which gives an indication of the engine load. The MAP sensor has a 5-volt reference circuit, a low reference circuit, and a signal circuit. The powertrain control module (PCM) supplies 5 volts to the MAP sensor on the 5-volt reference circuit and provides a ground on the low reference circuit. The MAP sensor provides a signal to the PCM on the MAP sensor signal circuit, which is relative to the pressure changes in the manifold. With low MAP, such as during idle or deceleration, the PCM should detect a low MAP sensor signal voltage. With high MAP, such as ignition ON, engine OFF, or wide open throttle (WOT), the PCM should detect a high MAP sensor signal voltage. This MAP sensor will indicate pressure between 10-104 kPa. The MAP sensor is also used in order to calculate the barometric pressure (BARO) when the ignition switch is turned ON, with the engine OFF. The BARO reading may also be updated whenever the engine is operated at WOT. The PCM monitors the MAP sensor signal for voltage outside of the normal range. If the PCM detects a MAP sensor signal voltage that is excessively low, DTC P0107 sets. If the PCM detects a MAP sensor signal voltage that is excessively high, DTC P0108 sets. TEST DESCRIPTION Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3596 Steps 4-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3597 Steps 6-10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3598 Steps 11-14 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3599 Steps 15-16 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3600 Steps 17-22 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3601 Steps 23-29 The number below refers to the step number on the diagnostic table. 4. This step tests the MAP sensor's ability to correctly indicate BARO. 12. The measurement noted in this step will be used in subsequent steps if the measurement does not exceed the specified value. 15. This step calculates the resistance in the 5-volt reference circuit. 16. This step calculates the resistance in the low reference circuit. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Locations > Page 3602 Manifold Pressure/Vacuum Sensor: Service and Repair MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR REPLACEMENT On the L36, the manifold absolute pressure (MAP) sensor is mounted to the positive crankcase ventilation (PCV) valve cover. Removal Procedure 1. Remove the fuel injector sight shield. 2. Disconnect the MAP sensor electrical connector. 3. Carefully release the locking tabs holding the MAP (1) sensor to the PCV valve cover (2) just enough to remove the MAP sensor. 4. Pull the MAP sensor straight out of PCV valve cover. Installation Procedure 1. Ensure that the seal is installed on the MAP sensor and that the seal is not damaged. 2. Position and install the MAP sensor (1) to the PCV valve cover (2). Ensure that the locking tabs engage to hold the MAP sensor to the PCV valve cover. 3. Connect the MAP sensor electrical connector. 4. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations Oil Level Sensor For ECM: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 3606 Lower Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 3607 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Level Sensor For ECM > Component Information > Locations > Page 3608 Engine Oil Level Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oil Pressure Sensor > Component Information > Service and Repair Oil Pressure Sensor: Service and Repair Engine Oil Pressure Sensor and/or Switch Replacement Removal Procedure 1. Raise and support the vehicle. 2. Disconnect the engine oil pressure switch electrical connector. 3. Remove the oil pressure switch. Installation Procedure Notice; Refer to Fastener Notice in Service Precautions. 1. Install the engine oil pressure switch. - Tighten the switch to 16 Nm (12 ft. lbs.). 2. Connect the engine oil pressure switch electrical connector. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations Upper Left Rear Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3615 Oxygen Sensor: Diagrams Heated Oxygen Sensor (HO2S) Sensor 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Page 3616 Heated Oxygen Sensor (HO2S) Sensor 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) 1 Replacement Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 1 Replacement HEATED OXYGEN SENSOR (HO2S) 1 REPLACEMENT TOOLS REQUIRED J 39194 Oxygen Sensor Wrench NOTE: The Heated Oxygen Sensor (HO2S) and the Oxygen Sensor use a permanently attached pigtail and connector. Do not remove this pigtail from the Heated Oxygen Sensor. Damage or the removal of the pigtail or the connector could affect the proper operation of the sensor. Take care when handling the HO2S and the O2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Also avoid using cleaning solvents of any type. Do not drop the HO2S or the O2S. Do not roughly handle the HO2S or the O2S. Removal Procedure NOTE: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. 1. Remove the fuel injector sight shield. 2. Remove the heated oxygen sensor (HO2S) electrical CPA retainer. 3. Disconnect the HO2S wiring harness connector (3) from the HO2S electrical connector (4). 4. Remove the HO2S electrical connector (4) from the fuel injector sight shield bracket (1). IMPORTANT: Remove the oxygen sensor with the engine temperature above 48°C (120°F). Otherwise the oxygen sensors may be difficult to remove. 5. Use the J 39194 to remove the HO2S (2). Installation Procedure NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: A special anti-seize compound is used on the oxygen sensor (1) threads. New service sensors should already have the compound applied to the threads. Coat the threads of a reused sensor with anti-seize compound P/N 12377953 or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) 1 Replacement > Page 3619 1. Install the rear oxygen sensor in the right exhaust manifold. Tighten Use the J 39194 to tighten the HO2S to 41 N.m (30 lb ft). 2. Connect the HO2S electrical connector (4) to the wiring harness connector (3). 3. Install the HO2S electrical connector (4) to the fuel injector sight shield bracket (1). 4. Install the HO2S electrical CPA retainer. 5. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) 1 Replacement > Page 3620 Oxygen Sensor: Service and Repair Heated Oxygen Sensor (HO2S) 2 Replacement HEATED OXYGEN SENSOR (HO2S) 2 REPLACEMENT TOOLS REQUIRED J 39194 Oxygen Sensor Wrench NOTE: The Heated Oxygen Sensor (HO2S) and the Oxygen Sensor use a permanently attached pigtail and connector. Do not remove this pigtail from the Heated Oxygen Sensor. Damage or the removal of the pigtail or the connector could affect the proper operation of the sensor. Take care when handling the HO2S and the O2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Also avoid using cleaning solvents of any type. Do not drop the HO2S or the O2S. Do not roughly handle the HO2S or the O2S. Removal Procedure NOTE: The oxygen sensor may be difficult to remove when the engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold or the exhaust pipe. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the HO2S electrical connector retaining tab (1) from the HO2S electrical connector (2). 3. Disconnect the HO2S electrical connector from the HO2S electrical connector (2). 4. Use the J 39194 to remove the HO2S from the exhaust pipe. Installation Procedure NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: A special anti-seize compound is used on the oxygen sensor threads. New service sensors should already have the compound applied to the threads. Coat the threads of a reused sensor with anti-seize compound P/N 12377953 or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Heated Oxygen Sensor (HO2S) 1 Replacement > Page 3621 1. Install the oxygen sensor (4) to the exhaust pipe. Tighten Use the J 39194 to tighten the oxygen sensor to 41 N.m (30 lb ft). 2. Connect the HO2S connector (4) to the HO2S electrical connector (2). 3. Install the retaining tab (1) to the HO2S electrical connector. 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set Throttle Position Sensor: Customer Interest Engine Controls - Intermittent Chuggle/No DTC's Set Bulletin No.: 05-06-04-058 Date: September 07, 2005 TECHNICAL Subject: Intermittent Chuggle or Fishbite on Light Acceleration or at Highway Speeds with No Diagnostic Trouble Codes (DTCs) (Replace Throttle Position ( TPS) Sensor) Models: 1995-1999 Buick Riviera 1995-2004 Buick Regal 1995-2005 Buick LeSabre, Park Avenue 1997-2005 Buick Century 1995-2001 Chevrolet Lumina 1995-2002 Chevrolet Camaro 1995-2005 Chevrolet Monte Carlo 2000-2005 Chevrolet Impala 1995-1997 Oldsmobile Cutlass Supreme, Ninety Eight 1995-1999 Oldsmobile Eighty Eight 1998-2002 Oldsmobile Intrigue 1995-2002 Pontiac Firebird 1995-2003 Pontiac Grand Prix 1995-2005 Pontiac Bonneville with 3800 V6 Engine (VIN K - RPO L36) Condition Some customers may comment on an intermittent chuggle or fishbite on light acceleration or at steady-state highway speeds (typically 80-105 km/h [50-65 mph]) with no PCM DTCs set. This condition may lead the technician to suspect the TCC circuit or torque converter. Cause This condition may be caused by intermittent operation of the Throttle Position (TPS) Sensor. Correction In observed cases, the Tech 2(R) is not fast enough to consistently detect this condition during a snapshot. It is recommended to use a DVOM set to the min/max recording mode. Connect the DVOM at the TPS connector (positive lead to TPS feedback signal pin and negative lead to TPS ground pin). Duplicate this condition by driving the vehicle. If the voltage dropout (less than 0.45 v) is recorded on the DVOM, replace the TPS sensor and re-evaluate the vehicle before continuing with other driveability or transmission diagnosis. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set > Page 3630 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set Throttle Position Sensor: All Technical Service Bulletins Engine Controls - Intermittent Chuggle/No DTC's Set Bulletin No.: 05-06-04-058 Date: September 07, 2005 TECHNICAL Subject: Intermittent Chuggle or Fishbite on Light Acceleration or at Highway Speeds with No Diagnostic Trouble Codes (DTCs) (Replace Throttle Position ( TPS) Sensor) Models: 1995-1999 Buick Riviera 1995-2004 Buick Regal 1995-2005 Buick LeSabre, Park Avenue 1997-2005 Buick Century 1995-2001 Chevrolet Lumina 1995-2002 Chevrolet Camaro 1995-2005 Chevrolet Monte Carlo 2000-2005 Chevrolet Impala 1995-1997 Oldsmobile Cutlass Supreme, Ninety Eight 1995-1999 Oldsmobile Eighty Eight 1998-2002 Oldsmobile Intrigue 1995-2002 Pontiac Firebird 1995-2003 Pontiac Grand Prix 1995-2005 Pontiac Bonneville with 3800 V6 Engine (VIN K - RPO L36) Condition Some customers may comment on an intermittent chuggle or fishbite on light acceleration or at steady-state highway speeds (typically 80-105 km/h [50-65 mph]) with no PCM DTCs set. This condition may lead the technician to suspect the TCC circuit or torque converter. Cause This condition may be caused by intermittent operation of the Throttle Position (TPS) Sensor. Correction In observed cases, the Tech 2(R) is not fast enough to consistently detect this condition during a snapshot. It is recommended to use a DVOM set to the min/max recording mode. Connect the DVOM at the TPS connector (positive lead to TPS feedback signal pin and negative lead to TPS ground pin). Duplicate this condition by driving the vehicle. If the voltage dropout (less than 0.45 v) is recorded on the DVOM, replace the TPS sensor and re-evaluate the vehicle before continuing with other driveability or transmission diagnosis. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set > Page 3636 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3637 Throttle Position Sensor: Locations Left Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3638 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3639 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3640 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3641 Throttle Position (TP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3642 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Remove the 2 TP sensor screws. 4. Remove the TP sensor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3643 1. Install the TP sensor to the throttle body assembly. 2. Apply thread-locking compound GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the TP sensor screws. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 2 TP sensor screws. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Connect the TP sensor electrical connector. 5. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Lower Right Rear Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3647 Vehicle Speed Sensor (VSS) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set Throttle Position Sensor: Customer Interest Engine Controls - Intermittent Chuggle/No DTC's Set Bulletin No.: 05-06-04-058 Date: September 07, 2005 TECHNICAL Subject: Intermittent Chuggle or Fishbite on Light Acceleration or at Highway Speeds with No Diagnostic Trouble Codes (DTCs) (Replace Throttle Position ( TPS) Sensor) Models: 1995-1999 Buick Riviera 1995-2004 Buick Regal 1995-2005 Buick LeSabre, Park Avenue 1997-2005 Buick Century 1995-2001 Chevrolet Lumina 1995-2002 Chevrolet Camaro 1995-2005 Chevrolet Monte Carlo 2000-2005 Chevrolet Impala 1995-1997 Oldsmobile Cutlass Supreme, Ninety Eight 1995-1999 Oldsmobile Eighty Eight 1998-2002 Oldsmobile Intrigue 1995-2002 Pontiac Firebird 1995-2003 Pontiac Grand Prix 1995-2005 Pontiac Bonneville with 3800 V6 Engine (VIN K - RPO L36) Condition Some customers may comment on an intermittent chuggle or fishbite on light acceleration or at steady-state highway speeds (typically 80-105 km/h [50-65 mph]) with no PCM DTCs set. This condition may lead the technician to suspect the TCC circuit or torque converter. Cause This condition may be caused by intermittent operation of the Throttle Position (TPS) Sensor. Correction In observed cases, the Tech 2(R) is not fast enough to consistently detect this condition during a snapshot. It is recommended to use a DVOM set to the min/max recording mode. Connect the DVOM at the TPS connector (positive lead to TPS feedback signal pin and negative lead to TPS ground pin). Duplicate this condition by driving the vehicle. If the voltage dropout (less than 0.45 v) is recorded on the DVOM, replace the TPS sensor and re-evaluate the vehicle before continuing with other driveability or transmission diagnosis. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set > Page 3656 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set Throttle Position Sensor: All Technical Service Bulletins Engine Controls - Intermittent Chuggle/No DTC's Set Bulletin No.: 05-06-04-058 Date: September 07, 2005 TECHNICAL Subject: Intermittent Chuggle or Fishbite on Light Acceleration or at Highway Speeds with No Diagnostic Trouble Codes (DTCs) (Replace Throttle Position ( TPS) Sensor) Models: 1995-1999 Buick Riviera 1995-2004 Buick Regal 1995-2005 Buick LeSabre, Park Avenue 1997-2005 Buick Century 1995-2001 Chevrolet Lumina 1995-2002 Chevrolet Camaro 1995-2005 Chevrolet Monte Carlo 2000-2005 Chevrolet Impala 1995-1997 Oldsmobile Cutlass Supreme, Ninety Eight 1995-1999 Oldsmobile Eighty Eight 1998-2002 Oldsmobile Intrigue 1995-2002 Pontiac Firebird 1995-2003 Pontiac Grand Prix 1995-2005 Pontiac Bonneville with 3800 V6 Engine (VIN K - RPO L36) Condition Some customers may comment on an intermittent chuggle or fishbite on light acceleration or at steady-state highway speeds (typically 80-105 km/h [50-65 mph]) with no PCM DTCs set. This condition may lead the technician to suspect the TCC circuit or torque converter. Cause This condition may be caused by intermittent operation of the Throttle Position (TPS) Sensor. Correction In observed cases, the Tech 2(R) is not fast enough to consistently detect this condition during a snapshot. It is recommended to use a DVOM set to the min/max recording mode. Connect the DVOM at the TPS connector (positive lead to TPS feedback signal pin and negative lead to TPS ground pin). Duplicate this condition by driving the vehicle. If the voltage dropout (less than 0.45 v) is recorded on the DVOM, replace the TPS sensor and re-evaluate the vehicle before continuing with other driveability or transmission diagnosis. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set > Page 3662 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3663 Throttle Position Sensor: Locations Left Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3664 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3665 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3666 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3667 Throttle Position (TP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3668 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Remove the 2 TP sensor screws. 4. Remove the TP sensor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3669 1. Install the TP sensor to the throttle body assembly. 2. Apply thread-locking compound GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the TP sensor screws. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 2 TP sensor screws. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Connect the TP sensor electrical connector. 5. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations Lower Right Rear Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations > Page 3673 Vehicle Speed Sensor (VSS) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalytic Converter Bypass Valve Actuator > Component Information > Service and Repair Catalytic Converter Bypass Valve Actuator: Service and Repair BYPASS VALVE ACTUATOR REPLACEMENT TOOLS REQUIRED J 39363 Supercharger Actuator Adjuster REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Remove the boost control solenoid. 3. Remove the vacuum hoses from the bypass actuator. 4. Remove the bypass valve actuator mounting bolts and rotate the bypass valve actuator until the rod disengages the lever. INSTALLATION PROCEDURE 1. Install the J 39363 to the actuator. IMPORTANT: When installing the bypass valve actuator to the supercharger, rotate the assembly until the bypass valve shaft lever comes in contact with the stop block. 2. Rotate the actuator until the rod engages the lever. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the bypass valve actuator bolts. Tighten Tighten the bolts to 25 N.m (18 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Catalytic Converter Bypass Valve Actuator > Component Information > Service and Repair > Page 3679 4. Remove the J 39363. 5. Install the vacuum hoses to the bypass actuator. 6. Install the boost control solenoid. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Canister Purge Solenoid: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3684 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3685 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3686 Left Rear Of Vehicle Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3687 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3688 Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3689 Evaporative Emissions (EVAP) Canister Purge Solenoid Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3690 Canister Purge Solenoid: Description and Operation EVAP CANISTER PURGE SOLENOID VALVE The EVAP canister purge solenoid valve controls the flow of vapors from the EVAP system to the intake manifold. This normally closed solenoid is pulse width modulated (PWM) by the control module to precisely control the flow of fuel vapor to the engine. The solenoid will also be opened during some portions of the EVAP testing, allowing engine vacuum to enter the EVAP system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3691 Canister Purge Solenoid: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER PURGE SOLENOID VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Disconnect the evaporative emission (EVAP) canister purge valve electrical connector. 3. Disconnect the EVAP canister purge valve purge pipe and vacuum supply hose. 4. Release the retaining tab on the EVAP canister purge mounting bracket and remove the EVAP canister purge valve. INSTALLATION PROCEDURE 1. Install the EVAP canister purge valve onto the EVAP canister purge valve mounting bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3692 2. Connect the EVAP canister purge valve purge pipe and vacuum supply hose. 3. Connect the EVAP canister purge valve electrical connector. 4. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations Left Rear Of Vehicle Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3697 Evaporative Emissions (EVAP) Canister Vent Solenoid Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3698 Canister Vent Valve: Description and Operation EVAP CANISTER VENT SOLENOID VALVE The EVAP canister vent solenoid valve controls fresh airflow into the EVAP canister. The valve is normally open. The control module will command the solenoid closed during some EVAP tests, allowing the system to be tested for leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emission Control Canister > Canister Vent Valve > Component Information > Locations > Page 3699 Canister Vent Valve: Service and Repair EVAPORATIVE EMISSION (EVAP) CANISTER VENT SOLENOID VALVE REPLACEMENT REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the evaporative emission (EVAP) vent valve electrical connector (1). 3. Remove the EVAP vent valve bracket bolt. 4. Remove the vent hose (4) from the EVAP vent valve. 5. Remove the EVAP vent valve from the bracket (2). INSTALLATION PROCEDURE 1. Install the EVAP vent valve to the bracket (2). 2. Install the vent hose (4) to the EVAP vent valve. 3. Install the EVAP vent valve and the bracket. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the EVAP vent valve bracket bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 5. Connect the EVAP vent valve electrical connector (1). 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP Hoses/Pipes Replacement Canister/Fuel Tank Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement - Canister/Fuel Tank EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CANISTER/FUEL TANK REMOVAL PROCEDURE 1. Remove the fuel tank. 2. Disconnect the evaporative emission (EVAP) vapor pipe (7) from the EVAP canister (1), the fill limiter vent valve, and the fuel sender assembly. 3. Remove the EVAP vapor pipe. INSTALLATION PROCEDURE 1. Position the EVAP vapor pipe on the fuel tank. 2. Connect the EVAP vapor pipe (7) to the EVAP canister (1), the fill limiter vent valve, and the fuel sender assembly. 3. Install the fuel tank. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP Hoses/Pipes Replacement Canister/Fuel Tank > Page 3704 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement Chassis/Canister EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - CHASSIS/CANISTER REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the evaporative emission (EVAP) purge pipe connector at the fuel filter area. 3. Disconnect the EVAP purge pipe (8) from the EVAP canister (1). 4. Remove the EVAP purge pipe (8). INSTALLATION PROCEDURE 1. Connect the EVAP purge pipe (8) to the EVAP canister. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP Hoses/Pipes Replacement Canister/Fuel Tank > Page 3705 2. Connect the EVAP purge pipe at the fuel filter area. 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Service and Repair > EVAP Hoses/Pipes Replacement Canister/Fuel Tank > Page 3706 Evaporative Emissions Hose: Service and Repair EVAP Hoses/Pipes Replacement Engine/Chassis EVAPORATIVE EMISSION (EVAP) HOSES/PIPES REPLACEMENT - ENGINE/CHASSIS REMOVAL PROCEDURE 1. Remove the fuel hose/pipe bundle. 2. Remove the evaporative emission (EVAP) purge pipe from the fuel bundle. INSTALLATION PROCEDURE 1. Install the EVAP purge pipe into the fuel bundle. 2. Install the fuel hose/pipe bundle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative System Service Port > Component Information > Description and Operation Evaporative System Service Port: Description and Operation EVAP SERVICE PORT The EVAP service port is located in the EVAP purge pipe between the EVAP canister purge solenoid valve and the EVAP canister. The service port is identified by a green colored cap. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Boost Control Solenoid > Component Information > Service and Repair EGR Boost Control Solenoid: Service and Repair BOOST CONTROL SOLENOID REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Disconnect the boost source and signal hoses from the boost control solenoid (2). 3. Disconnect the boost control solenoid electrical connector. 4. Remove the boost control solenoid nut. 5. Remove the boost control solenoid (2). INSTALLATION PROCEDURE 1. Install the boost control solenoid (2). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the boost control solenoid nut. Tighten Tighten the nut to 8 N.m (71 lb in). 3. Connect the boost control solenoid electrical connector. 4. Connect the boost source and signal hoses to the boost control solenoid (2). 5. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Inlet Pipe Replacement EGR Tube: Service and Repair Exhaust Gas Recirculation (EGR) Inlet Pipe Replacement EXHAUST GAS RECIRCULATION (EGR) INLET PIPE REPLACEMENT REMOVAL PROCEDURE 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the exhaust gas recirculation (EGR) valve inlet adapter pipe mounting bolt (2) from the exhaust manifold. 3. Lower the vehicle. 4. Remove the EGR valve. 5. Remove the EGR valve outlet pipe. 6. Remove the EGR valve inlet adapter pipe bolts (2,3). 7. Remove the EGR valve inlet adapter pipe (1). INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Inlet Pipe Replacement > Page 3718 1. Install the EGR valve inlet adapter pipe (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the EGR valve inlet adapter pipe bolts and studs (2,3). Tighten Tighten the bolt and stud to 50 N.m (37 lb ft). 3. Raise the vehicle. 4. Install the EGR valve inlet adapter pipe bolt (2) to the exhaust manifold. Tighten Tighten the bolt to 30 N.m (22 lb in). 5. Lower the vehicle. 6. Install the EGR valve outlet pipe. 7. Install the EGR valve. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Tube > Component Information > Service and Repair > Exhaust Gas Recirculation (EGR) Inlet Pipe Replacement > Page 3719 EGR Tube: Service and Repair Exhaust Gas Recirculation (EGR) Outlet Pipe Replacement EXHAUST GAS RECIRCULATION (EGR) OUTLET PIPE REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner intake duct. 2. Remove the exhaust gas recirculation (EGR) outlet pipe bolt (3) from the intake manifold. 3. Remove the EGR outlet pipe nut (2) from the EGR valve inlet adapter pipe. 4. Remove the EGR valve outlet pipe (1). INSTALLATION PROCEDURE 1. Install the EGR valve outlet pipe (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the EGR outlet pipe bolt (3) to the intake manifold. Tighten Tighten the bolt to 30 N.m (22 lb ft). 3. Install the EGR outlet pipe nut (2) to the EGR valve inlet adapter pipe. Tighten Tighten the nut to 30 N.m (22 lb ft). 4. Install the air cleaner intake duct. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams Exhaust Gas Recirculation (EGR) Valve Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Page 3723 EGR Valve: Service and Repair EXHAUST GAS RECIRCULATION (EGR) VALVE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the exhaust gas recirculation (EGR) valve electrical connector. 2. Remove the EGR valve nuts (4). 3. Remove the EGR valve (1). 4. Remove the gasket (2) from the EGR valve adapter. 5. Clean the EGR valve gasket mating surfaces. INSTALLATION PROCEDURE 1. Install a new EGR valve gasket (2). 2. Install the EGR valve (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Diagrams > Page 3724 NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the EGR valve nuts (4). Tighten Tighten the nuts to 30 N.m (22 lb ft). 4. Connect the EGR valve electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair Positive Crankcase Ventilation Valve: Service and Repair Positive Crankcase Ventilation (PCV) Valve Replacement Removal Procedure 1. Remove the fuel injector sight shield. 2. Disconnect the MAP sensor electrical connector. 3. Remove the MAP sensor (1). 4. Use a 16 mm (5/8 inch) socket to press the access cover (2) down and rotate 1/4 turn counterclockwise. 5. Remove the access cover. 6. Remove the PCV valve (3) and the O-ring (4) from the intake manifold. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Service and Repair > Page 3729 1. Install the new O-ring (4) and the PCV valve (3). 2. Install the access cover (2). 3. Install the MAP sensor (1). 4. Connect the MAP sensor electrical connector. 5. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 364-405 kPa (53-59 psi) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable.A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Remove the fuel injector sight shield. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Install the J 34730-1A to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3736 3. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gage. 7. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container. Open the bleed valve in order to bleed the fuel system pressure. 2. Place a shop towel under the fuel pressure gage in order to catch any remaining fuel spillage. 3. Remove the fuel pressure gage from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3737 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST DESCRIPTION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3738 Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3739 Steps 4-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3740 Steps 8-9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3741 Steps 10-11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3742 Steps 12-15 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3743 Steps 16-17 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3744 Steps 18-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3745 Steps 21-25 The numbers below refer to the step numbers on the diagnostic table. 2. This step verifies that the fuel pump is operating. 4. This step tests for an internal fuel leak. If the fuel pressure decreases during this test, an internal loss of pressure is indicated. 6. This step tests the fuel pressure regulator. The fuel pressure regulator is controlled by engine vacuum. With engine vacuum applied, the pressure should decrease by the specified value. 9. This step inspects the fuel pressure regulator for a fuel leak from the vacuum port. If fuel leaks from the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator. 10. This step tests for a loss of fuel pressure between the shut-off adapter on the fuel feed pipe and the fuel pump. 11. This step tests for a leaking fuel injector, or fuel pressure regulator. If the fuel pressure remains constant during this test, the fuel injectors are not leaking fuel. 14. This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, a restriction in the fuel return pipe is indicated. 16. This step determines if the fuel pressure regulator, or the fuel pump, is the cause of the low fuel pressure. If the pressure rises above the specified value, the fuel pump is OK. 18. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Inspect all fuel pump electrical circuits thoroughly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable.A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Remove the fuel injector sight shield. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Install the J 34730-1A to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3750 3. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gage. 7. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container. Open the bleed valve in order to bleed the fuel system pressure. 2. Place a shop towel under the fuel pressure gage in order to catch any remaining fuel spillage. 3. Remove the fuel pressure gage from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3751 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage RELIEF PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the fuel injector sight shield. 3. Loosen the fuel filler cap to relieve tank vapor pressure. 4. Connect the J 34730-1A to the fuel pressure connection. Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gage in order to avoid spillage. 5. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 6. Drain any fuel remaining in the fuel pressure gage into an approved container. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Specifications Idle Speed: Specifications Information not supplied by the manufacturer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component Information > Service and Repair Accelerator Pedal: Service and Repair ACCELERATOR CONTROLS PEDAL REPLACEMENT REMOVAL PROCEDURE 1. Remove the left instrument panel sound insulator. 2. Remove the accelerator cable (5) from the accelerator pedal (1). 3. Remove the bolt (3) and the stud (2) from the accelerator pedal (1). 4. Remove the accelerator pedal (1). INSTALLATION PROCEDURE 1. Position the accelerator pedal (1) to the bulkhead (4). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the accelerator pedal bolt (3) and the stud (2). Tighten Tighten the bolt and the stud to 5 N.m (44 lb in). 3. Install the accelerator cable (5) to the accelerator pedal (1). IMPORTANT: The throttle should operate freely without binding between a fully closed and a wide open throttle. 4. Verify for complete throttle opening and closing positions by operating the accelerator pedal. Inspect for proper carpet fit under the accelerator pedal. 5. Install the left instrument panel sound insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Cleaner Fresh Air Duct/Hose > Component Information > Service and Repair Air Cleaner Fresh Air Duct/Hose: Service and Repair AIR CLEANER INTAKE DUCT REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the intake air temperature (IAT) sensor electrical connector (3). 2. Remove the IAT sensor with a twisting and pulling motion. 3. Loosen the air cleaner intake duct clamp. 4. Remove the air cleaner intake duct from the air cleaner cover. 5. Remove the air cleaner intake duct from the throttle body. INSTALLATION PROCEDURE 1. Install the air cleaner intake duct to the throttle body. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the air cleaner intake duct to the air cleaner cover. Tighten Tighten the air cleaner duct clamp to 2 N.m (18 lb in). 3. Install the IAT sensor. 4. Connect the IAT sensor electrical connector (3). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: Customer Interest Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3770 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON Air Filter Element: All Technical Service Bulletins Engine, A/T - Shift/Driveability Concerns/MIL ON Bulletin No.: 04-07-30-013B Date: February 01, 2007 INFORMATION Subject: Automatic Transmission Shift, Engine Driveability Concerns or Service Engine Soon (SES) Light On as a Result of the Use of an Excessively/Over-Oiled Aftermarket, Reusable Air Filter Models: 2007 and Prior GM Cars and Light Duty Trucks 2007 and Prior Saturn Models 2003-2007 HUMMER H2 2006-2007 HUMMER H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-07-30-013A (Section 07 - Transmission/Transaxle). The use of an excessively/over-oiled aftermarket, reusable air filter may result in: Service Engine Soon (SES) light on Transmission shift concerns, slipping and damaged clutch(es) or band(s) Engine driveability concerns, poor acceleration from a stop, limited engine RPM range The oil that is used on these air filter elements may be transferred onto the Mass Air Flow (MAF) sensor causing contamination of the sensor. As a result, the Grams per Second (GPS) signal from the MAF may be low and any or all of the concerns listed above may occur. When servicing a vehicle with any of these concerns, be sure to check for the presence of an aftermarket reusable, excessively/over-oiled air filter. The MAF, GPS reading should be compared to a like vehicle with an OEM air box and filter under the same driving conditions to verify the concern. The use of an aftermarket reusable air filter DOES NOT void the vehicle's warranty. If an aftermarket reusable air filter is used, technicians should inspect the MAF sensor element and the air induction hose for contamination of oil prior to making warranty repairs. Transmission or engine driveability concerns (related to the MAF sensor being contaminated with oil) that are the result of the use of an aftermarket reusable, excessively/over-oiled air filter are not considered to be warrantable repair items. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 04-07-30-013B > Feb > 07 > Engine, A/T - Shift/Driveability Concerns/MIL ON > Page 3776 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 06-02-32-009B > Nov > 08 > Steering - Noise Diagnostics TSB References Power Steering Fluid: All Technical Service Bulletins Steering - Noise Diagnostics TSB References INFORMATION Bulletin No.: 06-02-32-009B Date: November 19, 2008 Subject: Overview of Steering System Noises Models: 2001-2004 Buick Regal 2001-2005 Buick Century 2005-2007 Buick Allure (Canada Only), LaCrosse 2000-2006 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 1998-2002 Oldsmobile Intrigue 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to remove reference to Corporate Bulletin Number 01-02-32-001 from the table below. Please discard Corporate Bulletin Number 06-02-32-009A (Section 02 - Steering). The purpose of this bulletin is to provide a quick reference for dealers to aid in locating the correct service bulletin for several different steering system noise concerns. Many customer concerns with the steering system involve specific symptoms (noises heard). Once the customer concern has been verified, the table above may help identify the correct bulletin to reference. If other symptoms are present, or if diagnosis indicates another cause not found in any of the three service bulletins, refer to SI to diagnose the repair customer concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise Power Steering Fluid: All Technical Service Bulletins Steering - Steering Gear Leaks/Moan or Groan Noise Bulletin No.: 05-02-32-007D Date: March 29, 2007 ENGINEERING INFORMATION Subject: EI05119 - Power Steering Gear Leak, Moan, Groan or Whine Noise (Diagnose and Repair as Necessary) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2004-2007 Chevrolet Impala, Monte Carlo 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to provide additional leak and noise diagnosis information. Please discard Corporate Bulletin Number 05-02-32-007C (Section 02 - Steering). Condition Some customers may comment on a power steering gear leak or that the gear appears to be leaking. Additionally, the customer may come into the dealership indicating they were told by an aftermarket service facility that the steering gear was leaking because the power steering reservoir was low on fluid and the gear showed an oil residue. Some customers may also comment on a power steering noise during steering maneuvers or while driving. Correction Inspect and diagnose the power steering system before any repairs are attempted using the procedure listed below. Because the power steering reservoir on 3800 V6-equipped vehicles is located behind and below the rear cylinder head, the fluid level may not be getting checked and/or topped off similar to other vehicles which have a reservoir that is located on the upper portion of the engine. This condition could be more prevalent with vehicles serviced at non-GM dealerships. Determine if the power steering system is full of oil. Adjust the fluid in the reservoir to the proper level. The lower fluid level could be the result of a variation in the original system fill. Plus, over time and mileage, the system purges any remaining air. Additionally, as the hoses expand and contract, the fluid level may drop as measured within the reservoir. Don't assume there is an external fluid leak just because the fluid level in the reservoir is down to the Add mark. Restart the engine and see if the noise goes away after turning the steering wheel lock to lock a few times. This will correct most, if not all, the vehicles with a noise condition. If the customer was told their was a power steering fluid leak by an aftermarket service facility because the power steering reservoir needed fluid and they saw oil residue on the power steering gear, then carefully inspect the gear and surrounding area for oil residue. Below are some causes as to why oil residue may be present. Oil residue on the body of the steering gear usually on the pinion area (left side) of the gear or on the convoluted boots. This condition could be caused by a small amount of oil that can drip out when the shipping plugs are removed from the gear, just prior to the installation of the P/S pressure and return lines being connected at the assembly plants. Gears should not be replaced for this condition. Oil residue on or near the pinion adjuster nut plug. During the gear assembly process the supplier uses grease to lubricate the pinion adjuster plug threads. In cases where a lot of grease was used on the adjuster plug threads, some grease can ooze out around the threads and when mixed with moisture and road grime, it can appear as though the plug is leaking. In some cases the heat generated from the exhaust system will start to liquefy some of the grease and cause it to run. Gears should not be replaced for this condition. Oil residue inside the convoluted boots. When the steering gear is assembled into the housing, grease is applied to the gear teeth. In some cases, if there is a lot of grease used, it will squeeze out of the gear teeth, soften and run down and collect in the bottom of the convolutes. This may have the appearance of a thick oil, especially in hot climates. Some technicians have seen this liquefied grease and thought is was power steering fluid. Gears should not be replaced for this condition. If the customer indicates that they have seen what they think was a leak, resembling oil residue, on their garage floor or driveway, or the technician sees Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise > Page 3786 drops of oil leaking, carefully inspect the power steering hydraulic system. The inspection should be performed while the engine is running and the steering wheel is rotated from lock to lock. If a leak is observed, then repair the source of the leak. If the noise is not the result of low power steering fluid, provide a complete description of when the noise happens and what type of noise it is; i.e. squeal, pop, clunk, tick, continuous rubbing, etc. If it is a pop or clunk noise, make sure you inspect the convoluted boots to determine if the inner tie rod is rubbing the boots. Replace the boot or boots only for this condition. If the noise is a clunk or pop noise and it's not the inner tie rod rubbing the convoluted boots, make sure to inspect the intermediate shaft for the slip stick condition. This should be done prior to replacing any steering gears. If amber/yellow tinted glasses and the "pen light" style of black light are used, the lithium in the grease will show up in greenish/yellow similar to the greenish/yellow dye used by many dealerships to test for leaks. Always use the black light recommended by GM Tools and clear glasses to inspect for dye in fluid leaks. If the source of the leak cannot be found by visual inspection, add dye, P/N 88861206 (in Canada, use P/N 88861259), and inspect the system using Black Light (J 28428-E or J 42220). The number of vehicles that will require a complete inspection using dye will be minimal based on the inspection of numerous steering gears returned for testing where the complaint was fluid leak and no leaks could be reproduced. If a steering gear is replaced because a leak was discovered using the dye test method, make sure the repair order has a description of where the leak was discovered. If the steering gear is replaced for a noise concern, make sure a complete description of the diagnosis appears on the repair order as described in Step 5 above. Steering gears replaced under warranty will continue to be on parts return and regional feedbacks will be processed on any gears which the customer complaint cannot be verified. Over 90% of all steering gears inspected have little or no explanation of the condition, the technician's diagnosis or reason for replacing the gears and/or did not have any indication that dye was used to find a leak. Parts Information Warranty Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > All Other Service Bulletins for Air Filter Element: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise > Page 3796 drops of oil leaking, carefully inspect the power steering hydraulic system. The inspection should be performed while the engine is running and the steering wheel is rotated from lock to lock. If a leak is observed, then repair the source of the leak. If the noise is not the result of low power steering fluid, provide a complete description of when the noise happens and what type of noise it is; i.e. squeal, pop, clunk, tick, continuous rubbing, etc. If it is a pop or clunk noise, make sure you inspect the convoluted boots to determine if the inner tie rod is rubbing the boots. Replace the boot or boots only for this condition. If the noise is a clunk or pop noise and it's not the inner tie rod rubbing the convoluted boots, make sure to inspect the intermediate shaft for the slip stick condition. This should be done prior to replacing any steering gears. If amber/yellow tinted glasses and the "pen light" style of black light are used, the lithium in the grease will show up in greenish/yellow similar to the greenish/yellow dye used by many dealerships to test for leaks. Always use the black light recommended by GM Tools and clear glasses to inspect for dye in fluid leaks. If the source of the leak cannot be found by visual inspection, add dye, P/N 88861206 (in Canada, use P/N 88861259), and inspect the system using Black Light (J 28428-E or J 42220). The number of vehicles that will require a complete inspection using dye will be minimal based on the inspection of numerous steering gears returned for testing where the complaint was fluid leak and no leaks could be reproduced. If a steering gear is replaced because a leak was discovered using the dye test method, make sure the repair order has a description of where the leak was discovered. If the steering gear is replaced for a noise concern, make sure a complete description of the diagnosis appears on the repair order as described in Step 5 above. Steering gears replaced under warranty will continue to be on parts return and regional feedbacks will be processed on any gears which the customer complaint cannot be verified. Over 90% of all steering gears inspected have little or no explanation of the condition, the technician's diagnosis or reason for replacing the gears and/or did not have any indication that dye was used to find a leak. Parts Information Warranty Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter Element > Component Information > Technical Service Bulletins > Page 3797 Air Filter Element: Service and Repair AIR CLEANER ELEMENT REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner intake duct . 2. Unclip the 2 air cleaner cover retaining clamps. 3. Remove the air cleaner housing cover (5). 4. Remove the air filter element (6). 5. Inspect the air cleaner housing cover (5), the seal assembly, and the air cleaner intake duct for damage. If a problem is found, replace as necessary. INSTALLATION PROCEDURE 1. Install the air filter element (6). 2. Install the air cleaner housing cover (5) and clip the housing cover retaining clamps. 3. Install the air cleaner intake duct. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations Left Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3801 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3802 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3803 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3804 Mass Air Flow (MAF) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3805 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. IMPORTANT: The mass air flow (MAF) sensor is attached to the throttle body assembly. 2. Disconnect the MAF sensor electrical connector (8). 3. Remove the MAF sensor screws (9). 4. Remove the MAF sensor (1). INSTALLATION PROCEDURE 1. Install the MAF sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF sensor screws (9). Tighten Tighten the screws to 3 N.m (27 lb in). 3. Connect the MAF sensor electrical connector (8). 4. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) Fuel: Technical Service Bulletins Fuel System - TOP TIER Detergent Gasoline (Canada) INFORMATION Bulletin No.: 05-06-04-022G Date: October 27, 2010 Subject: TOP TIER Detergent Gasoline Information and Available Brands (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - Canada ONLY Models: 2011 and Prior GM Passenger Cars and Trucks (Canada Only) Supercede: This bulletin is being revised to update the model years and include an additional gasoline brand as a TOP TIER source. Please discard Corporate Bulletin Number 05-06-04-022F (Section 06 - Engine/Propulsion System). In the U.S., refer to the latest version of Corporate Bulletin Number 04-06-04-047I. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by the Canadian General Standards Board (CGSB). Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. Intake valve: 16,093 km (10,000 mi) with TOP TIER Detergent Gasoline Intake valve: 16,093 km (10,000 mi) with Minimum Additive recommended by the CGSB Top Tier Fuel Availability Chevron was the first to offer TOP TIER Detergent Gasoline in Canada. Shell became the first national gasoline retailer to offer TOP TIER Detergent Gasoline across Canada. Petro-Canada began offering TOP TIER Detergent Gasoline nationally as of October 1, 2006. Sunoco began offering TOP TIER Detergent Gasoline in March of 2007. Esso began offering TOP TIER Detergent Gasoline in May of 2010. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 3810 Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards The following gasoline brands meet the TOP TIER Detergent Gasoline Standards in all octane grades : Chevron Canada (markets in British Columbia and western Alberta) - Shell Canada (nationally) - Petro-Canada (nationally) - Sunoco-Canada (Ontario) - Esso-Canada (nationally) What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency and no metallic additives. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent recommendations of Canadian standards and does not contain metallic additives, which can damage vehicle emission control components. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began in the U.S. and Canada on May 3, 2004. Some fuel marketers have already joined and introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: BMW, General Motors, Honda, Toyota, Volkswagen and Audi. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. In the U.S., government regulations require that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In Canada, gasoline standards recommend adherence to U.S. detergency requirements but do not require it. In fact, many brands of gasoline in Canada do not contain any detergent additive. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required or recommended, and no metallic additives are allowed. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency and the intentional addition of metallic additives is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Clean engines help provide optimal fuel economy and engine performance, and also provide reduced emissions. Also, the use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Who should use TOP TIER Detergent Gasoline? All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" recommended by Canadian standards. Those vehicles that have experienced deposit related concerns may especially benefit from use of TOP TIER Detergent Gasoline. More information on TOP TIER Detergent Gasoline can be found at this website, http://www.toptiergas.com/. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 3811 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 3812 Fuel: Technical Service Bulletins Fuel System - 'TOP TIER' Detergent Gasoline Information INFORMATION Bulletin No.: 04-06-04-047I Date: August 17, 2009 Subject: TOP TIER Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) - U.S. Only Models: 2010 and Prior GM Passenger Cars and Trucks (including Saturn) (U.S. Only) 2003-2010 HUMMER H2 (U.S. Only) 2006-2010 HUMMER H3 (U.S. Only) 2005-2009 Saab 9-7X (U.S. Only) Supercede: This bulletin is being revised to add model years and additional sources to the Top Tier Fuel Retailers list. Please discard Corporate Bulletin Number 04-06-04-047H (Section 06 Engine/Propulsion System). In Canada, refer to Corporate Bulletin Number 05-06-04-022F. A new class of fuel called TOP TIER Detergent Gasoline is appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by six automotive companies. All vehicles will benefit from using TOP TIER Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from the use of TOP TIER Detergent Gasoline. Intake valve: - 10,000 miles with TOP TIER Detergent Gasoline Intake valve: - 10,000 miles with Legal Minimum additive Gasoline Brands That Currently Meet TOP TIER Detergent Gasoline Standards As of August 1, 2009, all grades of the following gasoline brands meet the TOP TIER Detergent Gasoline Standards: - Chevron - Chevron-Canada - QuikTrip - Conoco Phillips 66 - 76 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 3813 - Shell - Shell-Canada - Entec Stations located in the greater Montgomery, Alabama area. - MFA Oil Company located throughout Missouri. - Kwik Trip, Inc. in Minnesota and Wisconsin and Kwik Star convenience stores in Iowa. The Somerset Refinery, Inc. at Somerset Oil stations in Kentucky. Aloha Petroleum - Tri-Par Oil Company - Turkey Hill Minit Markets - Texaco - Petro-Canada - Sunoco-Canada - Road Ranger located in Illinois, Indiana, Iowa, Kentucky, Missouri, Ohio and Wisconsin What is TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by six automotive companies that exceed the detergent requirements imposed by the EPA. Where Can TOP TIER Detergent Gasoline Be Purchased? The TOP TIER program began on May 3, 2004 and many fuel marketers have joined the program and have introduced TOP TIER Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, they will appear on a list of brands that meet the TOP TIER standards. Where Can I find the Latest Information on TOP TIER Fuel and Retailers? On the web, please visit www.toptiergas.com for additional information and updated retailer lists. Who developed TOP TIER Detergent Gasoline standards? TOP TIER Detergent Gasoline standards were developed by six automotive companies: Audi, BMW, General Motors, Honda, Toyota and Volkswagen. Why was TOP TIER Detergent Gasoline developed? TOP TIER Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet TOP TIER Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, TOP TIER was developed to give fuel marketers the opportunity to differentiate their product. Why did the six automotive companies join together to develop TOP TIER? All six corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of TOP TIER Detergent Gasoline? TOP TIER Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of TOP TIER Detergent Gasoline will help reduce deposit related concerns. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 3814 Fuel: Technical Service Bulletins Fuel System - E85 Fuel Usage Precautions Bulletin No.: 05-06-04-035C Date: July 30, 2007 INFORMATION Subject: Usage of E85 Fuels in GM Vehicles Models: 1997-2008 GM Passenger Cars and Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 1997-2008 Isuzu NPR Commercial Medium Duty Trucks 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add the 2008 model year and additional engines with E85 capability. Please discard Corporate Bulletin Number 05-06-04-035B (Section 06 Engine/Propulsion System). Customer Interest in E85 Fuel As the retail price of gasoline increases, some locations in the country are seeing price differentials between regular gasoline and E85 where E85 is selling for substantially less than regular grade gasoline. One result of this is that some customers have inquired if they are able to use E85 fuel in non-E85 compatible vehicles. Only vehicles designated for use with E85 should use E85 blended fuel. E85 compatibility is designated for vehicles that are certified to run on up to 85% ethanol and 15% gasoline. All other gasoline engines are designed to run on fuel that contains no more than 10% ethanol. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Using E85 Fuels in Non-Compatible Vehicles General Motors is aware of an increased number of cases where customers have fueled non-FlexFuel designated vehicles with E85. Fueling non-FlexFuel designated vehicles with E85, or with fuels where the concentration of ethanol exceeds the ASTM specification of 10%, will result in one or more of the following conditions: Lean Driveability concerns such as hesitations, sags and/or possible stalling. SES lights due to OBD codes. Fuel Trim codes P0171 and/or P0174. Misfire codes (P0300). Various 02 sensor codes. Disabled traction control or Stability System disabled messages. Harsh/Firm transmission shifts. Fuel system and/or engine mechanical component degradation. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. If the dealer suspects that a non-FlexFuel designated vehicle brought in for service has been fueled with E85, the fuel in the vehicle's tank should be checked for alcohol content with tool J 44175. If the alcohol content exceeds 10% the fuel should be drained and the vehicle refilled with gasoline - preferably one of the Top Tier brands. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 3815 Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. A complete list of GM's FlexFuel vehicles can be found in this Service Bulletin, or at www.livegreengoyellow.com. E85 Compatible Vehicles The only E85 compatible vehicles produced by General Motors are shown. Only vehicles that are listed in the E85 Compatible Vehicles section of this bulletin and/or www.livegreengoyellow.com are E85 compatible. All other gasoline and diesel engines are NOT E85 compatible. Use of fuel containing greater than 10% ethanol in non-E85 designated vehicles can cause driveability issues, service engine soon indicators as well as increased fuel system corrosion. Repairs to non-FlexFuel vehicles that have been fueled with E85 are not covered under the terms of the New Vehicle Warranty. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 3816 Fuel: Technical Service Bulletins Fuel System - E85 Refueling Station Information Bulletin No.: 06-06-04-030 Date: May 15, 2006 INFORMATION Subject: Locations of E85 Refueling Stations and Expanded E85 Information Models: 2007 and Prior GM Cars and Trucks Equipped for Flexible Fuel (E85) Attention: U.S. dealers - This bulletin should be directed to the Sales Manager as well as the Service Manager. Copies of this bulletin may be given to customers purchasing or considering the purchase of E85 capable vehicles, and may be left or posted in customer waiting areas. Canadian dealers - This bulletin is intended for the U.S. Market and provides only limited information relevant to the Canadian market. Customer Questions, Concerns and Refueling Locations for E85 Fuel Extensive information on E85 Ethanol based fuels can be found at www.livegreengoyellow.com . This General Motors site contains vital information that anticipates and answers customer questions and concerns about E85 fuel. Part of the information is a useful link that provides the location nationally of all E85 refueling stations. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Fuel System - TOP TIER Detergent Gasoline (Canada) > Page 3817 Fuel: Technical Service Bulletins Fuel - Top Tier Detergent Gasoline Information Bulletin No.: 04-06-00-047 Date: June 24, 2004 ADVANCED SERVICE INFORMATION Subject: Top Tier Detergent Gasoline (Deposits, Fuel Economy, No Start, Power, Performance, Stall Concerns) Models: 2005 and Prior All General Motors Passenger Cars and Trucks (U.S. Only) A new class of gasoline, called Top Tier Detergent Gasoline, will be appearing at retail stations of some fuel marketers. This gasoline meets detergency standards developed by four automotive companies. A description of the concept and benefits of Top Tier is provided in the following question and answer section. What is Top Tier Detergent Gasoline? Top Tier Detergent Gasoline is a new class of gasoline with enhanced detergency. It meets new, voluntary deposit control standards developed by four automotive companies that exceed the detergent requirements imposed by the EPA. Who developed Top Tier Detergent Gasoline standards? Top Tier Detergent Gasoline standards were developed by four automotive companies: BMW, General Motors, Honda and Toyota. Why was Top Tier Detergent Gasoline developed? Top Tier Detergent Gasoline was developed to increase the level of detergent additive in gasoline. The EPA requires that all gasoline sold in the U.S. contain a detergent additive. However, the requirement is minimal and in many cases, is not sufficient to keep engines clean. In order to meet Top Tier Detergent Gasoline standards, a higher level of detergent is needed than what is required by the EPA. Also, Top Tier was developed to give fuel marketers the opportunity to differentiate their product. Why did the four automotive companies join together to develop Top Tier? All four corporations recognized the benefits to both the vehicle and the consumer. Also, joining together emphasized that low detergency is an issue of concern to several automotive companies. What are the benefits of Top Tier Detergent Gasoline? Top Tier Detergent Gasoline will help keep engines cleaner than gasoline containing the "Lowest Additive Concentration" set by the EPA. Clean engines help provide optimal fuel economy and performance and reduced emissions. Also, use of Top Tier Detergent Gasoline will help reduce deposit related concerns. Who should use Top Tier Detergent Gasoline? All vehicles will benefit from using Top Tier Detergent Gasoline over gasoline containing the "Lowest Additive Concentration" set by the EPA. Those vehicles that have experienced deposit related concerns may especially benefit from use of Top Tier Detergent Gasoline. Where can Top Tier Detergent Gasoline be purchased? The Top Tier program began on May 3, 2004. Some fuel marketers have already joined and are making plans to introduce Top Tier Detergent Gasoline. This is a voluntary program and not all fuel marketers will offer this product. Once fuel marketers make public announcements, a list of all fuel marketers meeting Top Tier standards will be made available. For now, look for the "Top Tier" designation at the gas pump. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3818 Fuel: Specifications GASOLINE OCTANE Use regular unleaded gasoline with a posted octane of 87 or higher. If the octane is less than 87, you may get a heavy knocking noise when you drive. If this occurs, use a gasoline rated at 87 octane or higher as soon as possible. Otherwise, you might damage your engine. A little pinging noise when you accelerate or drive uphill is considered normal. This does not indicate a problem exists or that a higher-octane fuel is necessary. If you are using 87 octane or higher-octane fuel and hear heavy knocking, your engine needs service. GASOLINE SPECIFICATIONS It is recommended that gasoline meet specifications which were developed by automobile manufacturers around the world and contained in the World-Wide Fuel Charter which is available from the Alliance of Automobile Manufacturers at www.autoalliance.org/fuel_charter.htm. Gasoline meeting these specifications could provide improved driveability and emission control system performance compared to other gasoline. In Canada, look for the "Auto Makers' Choice" label on the pump. CALIFORNIA FUEL If your vehicle is certified to meet California Emission Standards (see the underhood emission control label), it is designed to operate on fuels that meet California specifications. If this fuel is not available in states adopting California emissions standards, your vehicle will operate satisfactorily on fuels meeting federal specifications, but emission control system performance may be affected. The malfunction indicator lamp may turn on (see Malfunction Indicator Lamp ) and your vehicle may fail a smog-check test. If this occurs, return to your authorized GM dealer for diagnosis. If it is determined that the condition is caused by the type of fuel used, repairs may not be covered by your warranty. ADDITIVES To provide cleaner air, all gasoline in the United States are now required to contain additives that will help prevent engine and fuel system deposits from forming, allowing your emission control system to work properly. You should not have to add anything to your fuel. However, some gasoline contain only the minimum amount of additive required to meet U.S. Environmental Protection Agency regulations. General Motors recommends that you buy gasoline that are advertised to help keep fuel injectors and intake valves clean. If your vehicle experiences problems due to dirty injectors or valves, try a different brand of gasoline. Gasoline containing oxygenates, such as ethers and ethanol, and reformulated gasoline may be available in your area to contribute to clean air. General Motors recommends that you use these gasoline, particularly if they comply with the specifications described earlier. NOTICE: Your vehicle was not designed for fuel that contains methanol. Do not use fuel containing methanol. It can corrode metal parts in your fuel system and also damage the plastic and rubber parts. That damage would not be covered under your warranty. Some gasoline that are not reformulated for low emissions may contain an octane-enhancing additive called methylcyclopentadienyl manganese tricarbonyl (MMT); ask the attendant where you buy gasoline whether the fuel contains MMT. General Motors does not recommend the use of such gasoline Fuels containing MMT can reduce the life of spark plugs and the performance of the emission control system may be affected. The malfunction indicator lamp may turn on. If this occurs, return to your authorized GM dealer for service. FUELS IN FOREIGN COUNTRIES If you plan on driving in another country outside the United States or Canada, the proper fuel may be hard to find. Never use leaded gasoline or any other fuel not recommended in the previous text on fuel. Costly repairs caused by use of improper fuel would not be covered by your warranty. To check the fuel availability, ask an auto club, or contact a major oil company that does business in the country where you will be driving. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Alcohol/Contaminants-In-Fuel Diagnosis (With Special Tool) Fuel: Testing and Inspection Alcohol/Contaminants-In-Fuel Diagnosis (With Special Tool) ALCOHOL/CONTAMINANTS-IN-FUEL DIAGNOSIS (WITH SPECIAL TOOL) TEST DESCRIPTION Fuel quality can affect vehicle performance. Gasoline and gasoline blends that are contaminated or contain excessive amounts of alcohol can affect vehicle driveability, fuel economy, fuel system components and emissions. Excessive alcohol in the fuel may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Some types of alcohol are more detrimental to fuel system components than others. Ethanol is commonly used in gasoline, but in concentrations of no more than 10 percent. Some fuels, such as E85, contain a very high percentage of ethanol. Fuel with more than 10 percent ethanol may cause driveability conditions in vehicles such as hesitation, lack of power, stalling, or no start. If excessive alcohol in the fuel is suspected, then use the following procedure to test the fuel quality. TEST PROCEDURE 1. Turn ON the J 44175 Fuel Composition Tester. 2. Verify the fuel composition tester is operational by measuring the AC frequency output with a DMM. Refer to Measuring Frequency in Diagnostic Aids. A frequency without a fuel sample in the test cell indicates that the tester is working correctly. 3. Install the fuel pressure gage. IMPORTANT: Bleed the fuel pressure gage a few times in order to obtain an accurate fuel sample. 4. Close the bleed valve on the fuel pressure gage. 5. Place the bleed hose (1) of the fuel pressure gage into the 100 ml beaker (2). 6. Command the fuel pump ON with a scan tool. 7. Slowly open the bleed valve on the fuel pressure gage, until an adequate fuel sample is obtained. 8. If water appears in the fuel sample, replace the fuel in the vehicle. Refer to Fuel System Cleaning. IMPORTANT: DO NOT allow any substances other than gasoline, ethanol/gasoline blends, air, or acetone into the test ports of the fuel composition tester. Contaminants in the J 44175 could result in a misdiagnosis. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Alcohol/Contaminants-In-Fuel Diagnosis (With Special Tool) > Page 3821 9. Pour the fuel sample from the beaker (1) into the J 44175 , until the level of the fuel is at the top of each fuel test port (2). 10. Observe the diagnostic LEDs on the fuel composition tester.If the red fuel diagnostic LED is illuminated, a fuel contamination condition exists. Refer to Fuel System Cleaning. 11. Measure the output frequency of the fuel composition tester. Fuel Composition Test Examples 12. Subtract 50 from the reading on the DMM to obtain the percentage of alcohol in the fuel sample. Refer to the examples in the table. 13. If the fuel sample contains more than 10 percent ethanol, replace the fuel in the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Alcohol/Contaminants-In-Fuel Diagnosis (With Special Tool) > Page 3822 Fuel: Testing and Inspection Alcohol/Contaminants-In-Fuel Diagnosis (Without Special Tool) ALCOHOL/CONTAMINANTS-IN-FUEL DIAGNOSIS (WITHOUT SPECIAL TOOL) Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start, or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel rail, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system components for rust, or deterioration. Alcohol concentrations of more than 10 percent in the fuel can be detrimental to fuel system components. Alcohol contamination may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter restriction. Fuel contaminated with alcohol may cause driveability conditions such as hesitation, lack of power, stalling, or no start. Some types of alcohol are more detrimental to fuel system components than others. Alcohol In Fuel Testing Procedure The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If alcohol contamination is suspected then use the following procedure to test the fuel quality. 1. Using a 100 ml (3.38 oz) specified cylinder with 1 ml (0.034 oz) graduation marks, fill the cylinder with fuel to the 90 ml (3.04 oz) mark. 2. Add 10 ml (0.34 oz) of water in order to bring the total fluid volume to 100 ml (3.38 oz) and install a stopper. 3. Shake the cylinder vigorously for 10-15 seconds. 4. Carefully loosen the stopper in order to release the pressure. 5. Re-install the stopper and shake the cylinder vigorously again for 10-15 seconds. 6. Put the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation. If alcohol is present in the fuel, the volume of the lower layer, which would now contain both alcohol and water, will be more than 10 ml (0.34 oz). For example, if the volume of the lower layer is increased to 15 ml (0.51 oz), this indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because this procedure does not extract all of the alcohol from the fuel. Particulate Contaminants in Fuel Testing Procedure The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected. The sample should be bright and clear. If the sample appears cloudy, or contaminated with water as indicated by a water layer at the bottom of the sample, use the following procedure to diagnose the fuel. 1. Using an approved fuel container, draw approximately 0.5 litre (0.53 quart) of fuel. 2. Place the cylinder on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination. 3. Particulate contamination will show up in various shapes and colors. Sand will typically be identified by a white or light brown crystals. Rubber will appear as black and irregular particles. 4. Observe the fuel sample. If any physical contaminants or water are present, then clean the fuel system. Refer to Fuel System Cleaning. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Testing and Inspection > Page 3823 Fuel: Service and Repair FUEL SYSTEM CLEANING NOTE: Refer to Cover and Plug Openings Notice in Service Precautions. IMPORTANT: When flushing the fuel tank, treat the fuel and water mixture as a hazardous material. Handle the material in accordance with all local, state and federal laws and regulations. - Whenever the fuel tank is cleaned, inspect the fuel pump fuel strainer. If the fuel pump fuel strainer is contaminated, replace the fuel pump fuel strainer and inspect the fuel pump. - Always maintain cleanliness when servicing fuel system components. 1. Remove the fuel tank. 2. Inspect the fuel pump inlet for dirt and debris. If dirt and debris are found, replace the fuel pump. 3. Flush fuel tank with hot water. 4. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to ensure that the removal of the water from the fuel tank is complete. 5. Allow tank to dry completely before reassembly. 6. Install the fuel sender assembly. 7. Install the fuel tank. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component Information > Description and Operation Fuel Filler Cap: Description and Operation FUEL FILLER CAP NOTE: If a fuel tank filler cap requires replacement, use only a fuel tank filler cap with the same features. Failure to use the correct fuel tank filler cap can result in a serious malfunction of the fuel and EVAP system. The fuel fill pipe has a tethered quarter-turn type fuel filler cap. A torque-limiting device prevents the cap from being over tightened. To install the cap, turn the cap clockwise until you hear audible clicks. This indicates that the cap is correctly torqued and fully seated. A fuel filler cap that is not fully seated may cause a malfunction in the emission system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal Fuel Pressure Release: Service and Repair Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable.A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Remove the fuel injector sight shield. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Install the J 34730-1A to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3832 3. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gage. 7. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container. Open the bleed valve in order to bleed the fuel system pressure. 2. Place a shop towel under the fuel pressure gage in order to catch any remaining fuel spillage. 3. Remove the fuel pressure gage from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service and Repair > Fuel Pressure Gage Installation and Removal > Page 3833 Fuel Pressure Release: Service and Repair Fuel Pressure Relief Procedure FUEL PRESSURE RELIEF PROCEDURE TOOLS REQUIRED J 34730-1A Fuel Pressure Gage RELIEF PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the negative battery cable. 2. Remove the fuel injector sight shield. 3. Loosen the fuel filler cap to relieve tank vapor pressure. 4. Connect the J 34730-1A to the fuel pressure connection. Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gage in order to avoid spillage. 5. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing. 6. Drain any fuel remaining in the fuel pressure gage into an approved container. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel System - Fuel Injector Maintenance Cleaning Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Maintenance Cleaning Bulletin No.: 04-06-04-051B Date: January 04, 2006 INFORMATION Subject: Maintenance Cleaning of Fuel Injectors Models: 2006 and Prior All General Motors Passenger Cars and Trucks 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add models and model years and update the name and part number of GM Fuel System Treatment. Please discard Corporate Bulletin Number 04-06-04-051A (Section 06 - Engine/Propulsion System). General Motors is aware that some companies are marketing tools, equipment and programs to support fuel injector cleaning as a preventative maintenance procedure. General Motors does not endorse, support or acknowledge the need for fuel injector cleaning as a preventative maintenance procedure. Fuel injector cleaning is approved only when performed as directed by a published GM driveability or DTC diagnostic service procedure. Due to variation in fuel quality in different areas of the country, the only preventative maintenance currently endorsed by GM regarding its gasoline engine fuel systems is the addition of GM Fuel System Treatment PLUS, P/N 88861011 (for U.S. ACDelco(R), use P/N 88861013) (in Canada, P/N 88861012), added to a tank of fuel at each oil change. Refer to Corporate Bulletin Number 03-06-04-030A for proper cleaning instructions. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector #1 Fuel Injector 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector #1 > Page 3840 Fuel Injector 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector #1 > Page 3841 Fuel Injector 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector #1 > Page 3842 Fuel Injector 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector #1 > Page 3843 Fuel Injector: Diagrams Fuel Injector 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector #1 > Page 3844 Fuel Injector 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector #1 > Page 3845 Fuel Injector 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector #1 > Page 3846 Fuel Injector 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector #1 > Page 3847 Fuel Injector 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Fuel Injector #1 > Page 3848 Fuel Injector 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3849 Fuel Injector: Description and Operation FUEL INJECTORS The fuel injector assembly is a solenoid operated device, controlled by the PCM, that meters pressurized fuel to a single engine cylinder. The PCM energizes the high-impedance (12.0 ohms) injector solenoid (2) to open a normally closed ball valve (3). This allows fuel to flow into the top of the injector, past the ball valve, and through a director plate at the injector outlet. The director plate has four machined holes that control the fuel flow, generating a spray of finely atomized fuel at the injector tip. Fuel from the injector tip is directed at the intake valve, causing the fuel to become further atomized and vaporized before entering the combustion chamber. An injector stuck partly open can cause a loss of pressure after engine shutdown. Consequently, long cranking times would be noticed on some engines. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test Fuel Injector: Testing and Inspection Fuel Injector Coil Test FUEL INJECTOR COIL TEST CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector on the intake stroke for each cylinder. Ignition voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high, or low, will affect engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings increases as the temperature of the fuel injector increases. DIAGNOSTIC AIDS - Monitoring the misfire current counters, or misfire graph, may help isolate the fuel injector that is causing the condition. - Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the condition. - Perform the fuel injector coil test within the conditions of the customers concern. A fuel injector condition may only be apparent at a certain temperature, or under certain conditions. - If the fuel injector coil test does not isolate the condition perform the fuel injector balance test. Refer to Fuel Injector Balance Test with Special Tool or Fuel Injector Balance Test with Tech 2. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics TEST DESCRIPTION Steps 1-4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3852 Steps 5-7 The numbers below refer to the step numbers on the diagnostic table. 3. This step tests each fuel injector resistance within a specific temperature range. If any of the fuel injectors display a resistance outside of the specified value, replace the fuel injector. 4. This step determines if all of the fuel injectors are within 3 ohms of each other. If the highest resistance value is within 3 ohms of the lowest resistance value, then all of the fuel injector coil windings are OK. 5. This step determines which fuel injector is faulty. After subtracting the highest and lowest resistance values from the average value, replace the fuel injector that has the greatest resistance difference from the average. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3853 Fuel Injector: Testing and Inspection Fuel Injector Balance Test With special Tool FUEL INJECTOR BALANCE TEST WITH SPECIAL TOOL Fuel Injector Balance Test With Special Tool Fuel Injector Balance Test Example (Typical) SYSTEM DESCRIPTION The scan tool is first used to energize the fuel pump relay. The fuel injector tester is then used to pulse each injector for a precise amount of time, allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3854 Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3855 Steps 4-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3856 Step 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3857 Steps 7-8 The numbers below refer to the step numbers on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. 6. If the pressure drop value for each fuel injector is within 10 kPa (1.5 psi) of the average pressure drop value, the fuel injectors are flowing properly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3858 Fuel Injector: Testing and Inspection Fuel Injector Balance Test with Tech 2 FUEL INJECTOR BALANCE TEST WITH TECH 2 CIRCUIT DESCRIPTION The scan tool first energizes the fuel pump and then the injectors for a precise amount of time allowing a measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each injector. TEST DESCRIPTION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3859 Steps 1-4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3860 Step 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3861 Step 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3862 Steps 7-8 The numbers below refer to the step numbers on the diagnostic table. 3. The engine coolant temperature (ECT) must be below the operating temperature in order to avoid irregular fuel pressure readings due to hot soak fuel boiling. 6. If the pressure drop value for each fuel injector is within 10 kPa (1.5 psi) of the average pressure drop value, the fuel injectors are flowing properly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3863 Fuel Injector: Testing and Inspection Fuel Injector Circuit Diagnosis FUEL INJECTOR CIRCUIT DIAGNOSIS CIRCUIT DESCRIPTION The control module enables the appropriate fuel injector on the intake stroke for each cylinder. An ignition 1 voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. DIAGNOSTIC AIDS - Monitoring the fuel injector circuit status with a scan tool, while moving the fuel injector harness, may help to isolate an intermittent condition. - Performing the Fuel Injector Coil Test may help isolate an intermittent condition. Refer to Fuel Injector Coil Test. See: Computers and Control Systems/Testing and Inspection/Component Tests and General Diagnostics - For an intermittent condition, refer to Intermittent Conditions. See: Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies TEST DESCRIPTION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Testing and Inspection > Fuel Injector Coil Test > Page 3864 Steps 1-8 The numbers below refer to the step numbers on the diagnostic table. 4. This step tests for a short to ground on the ignition 1 voltage supply circuit of the fuel injector. 5. This step tests for an open ignition 1 voltage supply circuit between the injector fuse and a fuel injector electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure Fuel Injector: Service and Repair Fuel Injector Cleaning Procedure FUEL INJECTOR CLEANING PROCEDURE TOOLS REQUIRED - J 37287 Fuel Line Shut-Off Adapters - J 38500-A Fuel Injector Cleaner - J 42873-1 3/8 Fuel Line Shut-Off Adapter - J 42873-2 5/16 Fuel Line Shut-Off Adapter - J 42964-1 3/8 Fuel Line Shut-Off Adapter - J 42964-2 5/16 Fuel Line Shut-Off Adapter IMPORTANT: - GM Top-Engine Cleaner is the only injector cleaning agent recommended. Do not use other cleaning agents, as they may contain methanol which can damage fuel system components. - Under NO circumstances should the top engine cleaner be added to the vehicles fuel tank, as it may damage the fuel pump and other system components. - Do not exceed a 10 percent cleaning solution concentration. Higher concentrations may damage fuel system components. Testing has demonstrated that exceeding the 10 percent cleaning solution concentration does not improve the effectiveness of this procedure. - During this procedure you will need a total of 960 ml (32.4 oz) of cleaning solution. That is 2 tanks of solution for the J 38500-A . Other brands of tools may have a different capacity and would therefore require more or less tanks to complete the procedure. You must use all 960 ml (32.4 oz) of solution to insure complete injector cleaning. 1. Obtain J 38500-A (2). IMPORTANT: Make sure the valve at the bottom of the canister (3) is closed. 2. For US dealers, empty 2 pre-measured GM Top-Engine Cleaner containers, 24 ml (0.812 oz) each, GM P/N 12346535, into the J 38500-A. 3. For Canadian dealers, measure and dispense 48 ml (1.62 oz) of Top-Engine Cleaner, Canadian P/N 992872, into the J 38500-A. 4. If you are using any other brand of tank you will need a total of 96 ml (3.24 oz) of Top-Engine Cleaner mixed with 864 ml (29.16 oz) of regular unleaded gasoline. 5. Fill the injector cleaning tank with regular unleaded gasoline. Be sure to follow all additional instructions provided with the tool. 6. Electrically disable the vehicle fuel pump by removing the fuel pump relay and disconnecting the oil pressure switch connector, if equipped. 7. Disconnect the fuel feed and return lines at the fuel rail. Plug the fuel feed and return lines coming off the fuel rail with J 37287 , or J 42964-1 , and J 42964-2 , or J 42873-1 and J 42873-2 as appropriate for the fuel system. 8. Connect the J 38500-A to the vehicle's fuel rail. 9. Pressurize the J 38500-A to 510 kPa (75 psi). 10. Start and idle the engine until it stalls, due to lack fuel. This should take approximately 15-20 minutes. 11. Disconnect J 38500-A from the fuel rail. 12. Reconnect the vehicle's fuel pump relay and oil pressure switch connector, if equipped. 13. Remove J 37287 , or J 42964-1 , and J 42964-2 , or J 42873-1 and J 42873-2 and reconnect the vehicles fuel feed and return lines. 14. Start and idle the vehicle for an additional 2 minutes to ensure residual injector cleaner is flushed from the fuel rail and fuel lines. 15. Repeat steps 1-5 of the Injector Balance Test, and record the fuel pressure drop from each injector. 16. Subtract the lowest fuel pressure drop from the highest fuel pressure drop. If the value is 15 kPa (2 psi) or less, no additional action is required. If the value is greater than 15 kPa (2 psi), replace the injector with the lowest fuel pressure drop. 17. Add one ounce of Port Fuel Injector Cleaner, GM P/N 12345104 (Canadian P/N 10953467), to the vehicles fuel tank for each gallon of gasoline Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 3867 estimated to be in the fuel tank. Instruct the customer to add the reminder of the bottle of Port Fuel Injector Cleaner to the vehicle fuel tank at the next fill-up. 18. Advise the customer to change brands of fuel and to add GM Port Fuel Injector Cleaner every 5000 km (3,000 mi). GM Port Fuel Injector Cleaner contains the same additives that the fuel companies are removing from the fuel to reduce costs. Regular use of GM Port Fuel Injector Cleaner should keep the customer from having to repeat the injector cleaning procedure. 19. Road test the vehicle to verify that the customer concern has been corrected. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 3868 Fuel Injector: Service and Repair Fuel Injector Replacement FUEL INJECTOR REPLACEMENT REMOVAL PROCEDURE NOTE: Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles. Do not immerse the fuel injector in any type of cleaner. The fuel injector is an electrical component and may be damaged by this cleaning method. IMPORTANT: The fuel injector is serviced as a complete assembly only. If the fuel injectors are found to be leaking, the engine oil may be contaminated with fuel. Fuel injector O-rings should always be replaced whenever fuel injectors are serviced. 1. Remove the fuel rail. 2. Remove the fuel injector retaining clip (1). 3. Remove the fuel injector (3). 4. Remove the fuel injector upper O-ring (2). 5. Remove the fuel injector lower O-ring (4). INSTALLATION PROCEDURE IMPORTANT: When ordering new fuel injectors, order the correct injector for the application being serviced. The fuel injector assembly (1) is stamped with a part number identification (2), a manufacturing date (3), a week code (1), and a production plant number (4). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 3869 1. Coat all new O-rings with clean engine oil before installing 2. Install the fuel injector lower O-ring (4). 3. Install the fuel injector upper O-ring (2). 4. Install the fuel injector (3) to the fuel rail. 5. Install the fuel injector retaining clip (1). 6. Install the fuel rail. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Service and Repair > Fuel Injector Cleaning Procedure > Page 3870 Fuel Injector: Service and Repair Fuel Injector Sight Shield Replacement Fuel Injector Sight Shield Replacement Removal Procedure 1. Clean the area around the tube/oil fill cap before removing the tube/oil fill cap in order to prevent contaminants from falling into the valve rocker arm cover opening. 2. Twist counterclockwise to unlock the tube/oil fill cap from the valve rocker arm cover. 3. Lift the fuel injector sight shield up at the front and slide the tab out of the engine bracket. 4. Replace the tube/oil fill cap in the valve rocker arm cover. Installation Procedure 1. Remove the tube/oil fill cap from the valve rocker arm cover. 2. Insert the tab of the fuel injector sight shield under the engine bracket. 3. Place the hole of the fuel injector sight shield onto the oil fill neck of the valve rocker arm cover. 4. Install the tube/oil fill cap into the valve rocker arm cover and twist clockwise in order to lock the detent on the tube into the notch in the cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Description and Operation Fuel Line Coupler: Description and Operation QUICK-CONNECT FITTINGS Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs inside the female connector hold the fittings together. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Metal Collar) QUICK CONNECT FITTING(S) SERVICE (METAL COLLAR) TOOLS REQUIRED J 37088-A Fuel Line Disconnect Tool Set REMOVAL PROCEDURE CAUTION: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. - Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. - Place a dry chemical (Class B) fire extinguisher nearby before performing any on-vehicle service procedures. Failure to follow these precautions may result in personal injury. NOTE: Refer to Cover and Plug Openings Notice in Service Precautions. IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Grasp both sides of the fitting. Twist the female connector 1/4 turn in each direction to loosen any dirt within the fitting. 3. Blow dirt out of the fitting using compressed air. 4. Choose the correct tool from J 37088-A for the size of the fitting. Insert the tool into the female connector, then push inward to release the locking tabs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 3876 5. Pull the connection apart. NOTE: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the connections for dirt and burrs. Clean or replace the components and assemblies as required. 6. Using a clean shop towel, wipe off the male pipe end. 7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean engine oil to the male pipe end. 2. Push both sides of the fitting together to cause the retaining tabs to snap into place. 3. Once installed, pull on both sides of the fitting to ensure that the connection is secure. 4. Tighten the fuel filler cap. 5. Reconnect the negative battery cable. 6. Inspect for leaks. 6.1. Turn ON the ignition for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 3877 6.4. Inspect for fuel leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 3878 Fuel Line Coupler: Service and Repair Quick Connect Fitting(S) Service (Plastic Collar) QUICK CONNECT FITTING(S) SERVICE (PLASTIC COLLAR) REMOVAL PROCEDURE CAUTION: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. - Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury. - Place a dry chemical (Class B) fire extinguisher nearby before performing any on-vehicle service procedures. Failure to follow these precautions may result in personal injury. NOTE: Refer to Cover and Plug Openings Notice in Service Precautions. IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure. 2. Grasp both sides of the quick-connect fitting. Twist quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. 3. Repeat for other fuel pipe fitting. 4. Use compressed air to blow out dirt from the quick-connect fittings at both ends. 5. Squeeze plastic tabs of male end connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component Information > Service and Repair > Quick Connect Fitting(S) Service (Metal Collar) > Page 3879 6. Pull the connection apart.Repeat the step for the other fitting. 7. Wipe off the male pipe end using a clean shop towel. 8. Clean or replace the components/assemblies, as required. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated. 1. Apply a few drops of clean oil to the male pipe end. 2. Push both sides of the quick-connect fitting together in order to cause the retaining tabs/fingers to snap into place. 3. Pull on both sides of the quick connect fitting in order to ensure that the connection is secure. 4. Tighten the fuel filler cap. 5. Connect negative battery cable. 6. Inspect for fuel leaks. 6.1. Turn ON the ignition for 2 seconds. 6.2. Turn OFF the ignition for 10 seconds. 6.3. Turn ON the ignition. 6.4. Inspect for fuel leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation Fuel Pressure Regulator: Description and Operation FUEL PRESSURE REGULATOR ASSEMBLY The fuel pressure regulator is a vacuum operated diaphragm relief valve with fuel pump pressure on one side and regulator spring pressure and intake manifold vacuum on the other side. The fuel pressure regulator maintains a constant pressure differential across the injectors at all times. The pressure regulator compensates for engine load by increasing fuel pressure as the engine vacuum drops. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 3883 Fuel Pressure Regulator: Service and Repair FUEL PRESSURE REGULATOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure. 2. Clean any dirt from the fuel pressure regulator retaining ring. 3. Remove the vacuum line from the pressure regulator. 4. Remove the snap ring (7). 5. Using a shop towel to catch any spilled fuel; lift and twist the fuel pressure regulator in order to remove the fuel pressure regulator (6) from the fuel pressure regulator housing (1). 6. Remove the small regulator O-ring (2). 7. Remove the regulator O-rings (4,5). 8. Cover the fuel pressure regulator housing (1) to prevent contamination from entering the fuel system. INSTALLATION PROCEDURE NOTE: Do not use compressed air in order to test or clean a fuel pressure regulator as damage to the fuel pressure regulator may result. - Clean the fuel pressure regulator filter screen with gasoline if necessary. - Do not immerse the fuel pressure regulator in a solvent bath in order to prevent damage to the fuel pressure regulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Description and Operation > Page 3884 1. Install the new O-rings on the fuel pressure regulator (6), if a new fuel pressure regulator is not being installed. Lubricate the O-rings lightly with clean engine oil. 2. Install the regulator O-rings (4,5). 3. Install the small regulator O-ring (2). 4. Install the fuel pressure regulator (6) in the fuel pressure regulator housing (1). 5. Install the snap ring (7). 6. Install the vacuum line to the fuel pressure regulator. 7. Tighten the fuel fill cap. 8. Connect the negative battery cable. 9. Inspect for leaks. 9.1. Turn ON the ignition for 2 seconds. 9.2. Turn OFF the ignition for 10 seconds. 9.3. Turn ON the ignition. 9.4. Inspect for fuel leaks. 10. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Specifications Fuel Pressure: Specifications Fuel Pressure (Key ON Engine OFF) .............................................................................................................................................. 364-405 kPa (53-59 psi) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal Fuel Pressure: Testing and Inspection Fuel Pressure Gage Installation and Removal FUEL PRESSURE GAGE INSTALLATION AND REMOVAL TOOLS REQUIRED J 34730-1A Fuel Pressure Gage INSTALLATION PROCEDURE CAUTION: Gasoline or gasoline vapors are highly flammable.A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby. 1. Remove the fuel injector sight shield. CAUTION: Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury. The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gage. Place the towel in an approved container when the connection of the fuel pressure gage is complete. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections 1. Install the J 34730-1A to the fuel pressure service connection, located on the fuel rail. 2. Turn ON the ignition. CAUTION: Do not drain the fuel into an open container. Never store the fuel in an open container due to the possibility of a fire or an explosion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3891 3. Place the bleed hose of the fuel pressure gage into an approved gasoline container. 4. Open the bleed valve on the fuel pressure gage in order to bleed the air from the fuel pressure gage. 5. Command the fuel pump ON with a scan tool. 6. Close the bleed valve on the fuel pressure gage. 7. Inspect for fuel leaks. REMOVAL PROCEDURE 1. Place the fuel pressure gage bleed hose into an approved container. Open the bleed valve in order to bleed the fuel system pressure. 2. Place a shop towel under the fuel pressure gage in order to catch any remaining fuel spillage. 3. Remove the fuel pressure gage from the fuel pressure connection. 4. Drain any fuel remaining in the fuel pressure gage into an approved container. 5. Inspect for leaks using the following procedure: 5.1. Turn ON the ignition, with the engine OFF for 2 seconds. 5.2. Turn OFF the ignition for 10 seconds. 5.3. Turn ON the ignition, with the engine OFF. 5.4. Inspect for fuel leaks. 6. Install the cap on the fuel pressure connection. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3892 Fuel Pressure: Testing and Inspection Fuel System Diagnosis FUEL SYSTEM DIAGNOSIS SYSTEM DESCRIPTION When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops. The fuel tank stores the fuel supply. The electric fuel pump supplies fuel through an in-line fuel filter to the fuel injection system. The pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system. A separate pipe returns unused fuel to the fuel tank. TEST DESCRIPTION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3893 Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3894 Steps 4-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3895 Steps 8-9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3896 Steps 10-11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3897 Steps 12-15 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3898 Steps 16-17 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3899 Steps 18-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > System Diagnosis > Fuel Pressure Gage Installation and Removal > Page 3900 Steps 21-25 The numbers below refer to the step numbers on the diagnostic table. 2. This step verifies that the fuel pump is operating. 4. This step tests for an internal fuel leak. If the fuel pressure decreases during this test, an internal loss of pressure is indicated. 6. This step tests the fuel pressure regulator. The fuel pressure regulator is controlled by engine vacuum. With engine vacuum applied, the pressure should decrease by the specified value. 9. This step inspects the fuel pressure regulator for a fuel leak from the vacuum port. If fuel leaks from the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator. 10. This step tests for a loss of fuel pressure between the shut-off adapter on the fuel feed pipe and the fuel pump. 11. This step tests for a leaking fuel injector, or fuel pressure regulator. If the fuel pressure remains constant during this test, the fuel injectors are not leaking fuel. 14. This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, a restriction in the fuel return pipe is indicated. 16. This step determines if the fuel pressure regulator, or the fuel pump, is the cause of the low fuel pressure. If the pressure rises above the specified value, the fuel pump is OK. 18. This step verifies that a circuit condition is not the cause of a fuel pressure concern. Inspect all fuel pump electrical circuits thoroughly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation Fuel Pump Pickup Filter: Description and Operation FUEL STRAINER The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants and to wick fuel. The fuel strainer is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an abnormal amount of sediment or water. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 3904 Fuel Pump Pickup Filter: Service and Repair FUEL STRAINER REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Remove the fuel sender assembly. 2. Note the strainer (3) position for future reference. 3. Support the reservoir with one hand. Grasp the strainer with the other hand. 4. Use a screwdriver to pry the strainer ferrule off the reservoir. 5. Discard the strainer. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Pickup Filter > Component Information > Description and Operation > Page 3905 1. Install the new strainer (4) to the reservoir. 2. Support the reservoir with one hand. Grasp the strainer with the other hand. Twist the strainer into position. 3. Install the fuel sender assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation Fuel Rail: Description and Operation FUEL RAIL ASSEMBLY 3.4L Fuel Rail Assembly 3.8L Fuel Rail Assembly The fuel rail assembly attaches to the engine intake manifold. The fuel rail assembly performs the following functions: - Positions the injectors in the intake manifold - Distributes fuel evenly to the injectors - Integrates the fuel pressure regulator with the fuel metering system Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 3909 Fuel Rail: Service and Repair FUEL RAIL ASSEMBLY REPLACEMENT REMOVAL PROCEDURE NOTE: Refer to Cover and Plug Openings Notice in Service Precautions. IMPORTANT: When servicing the fuel rail assembly, take precautions to prevent dirt and other contaminants from entering the fuel passages. Cap the fittings and plug the holes during servicing. - Always maintain cleanliness when servicing fuel system components. 1. Relieve the fuel pressure from the fuel system. Refer to Fuel Pressure Relief Procedure. 2. Clean the fuel rail assembly and connections. 3. Disconnect the fuel feed (1) and the return pipes (2) from the fuel rail. 4. Remove the vacuum line from the fuel pressure regulator. 5. Remove the wiring harness from the fuel rail. 6. Remove the EVAP purge solenoid from the EVAP purge solenoid bracket. 7. Remove the spark plug wires from the upper intake manifold and reposition the spark plug wires. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 3910 8. Disconnect the fuel injector electrical connectors. 3.8L Fuel Rail Assembly 9. Remove the fuel rail nuts. 10. Remove the fuel rail with equal force on both sides of the fuel rail. INSTALLATION PROCEDURE CAUTION: In order to reduce the risk of fire and personal injury that may result from a fuel leak, always install the fuel injector O-rings in the proper position. If the upper and lower O-rings are different colors (black and brown), be sure to install the black O-ring in the upper position and the brown O-ring in the lower position on the fuel injector. The O-rings are the same size but are made of different materials. NOTE: Refer to Fuel Rail Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 3911 1. The O-rings must be replaced on all components that are serviced. 2. Lightly oil the fuel injector O-rings with clean motor oil. 3. Place the fuel rail assembly on the intake manifold. 4. Seat the fuel injectors by HAND. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the fuel rail nuts. Tighten Tighten the nuts to 10 N.m (89 lb in). 6. Connect the fuel injector electrical connectors. 7. Install the spark plug wires to the upper intake manifold. 8. Install the EVAP purge solenoid to the EVAP purge solenoid bracket. 9. Install the wiring harness to the fuel rail. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component Information > Description and Operation > Page 3912 10. Connect the fuel feed (1) and the return (2) pipes to the fuel rail. 11. Install the vacuum line to the fuel pressure regulator. 12. Tighten the fuel fill cap. 13. Connect the negative battery cable. 14. Inspect for leaks. 14.1. Turn ON the ignition for 2 seconds. 14.2. Turn OFF the ignition for 10 seconds. 14.3. Turn ON the ignition. 14.4. Inspect for fuel leaks. 15. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation Fuel Supply Line: Description and Operation FUEL FEED AND RETURN PIPES The fuel feed pipe carries fuel from the fuel tank to the fuel rail assembly. The fuel return pipe carries fuel from the fuel rail assembly back to the fuel tank. The fuel pipes consist of 2 sections: The rear fuel pipe assemblies are located from the top of the fuel tank to the chassis fuel pipes. The rear fuel pipes are constructed of nylon. - The chassis fuel pipes are located under the vehicle and connect the rear fuel pipes to the fuel rail pipes. These pipes are constructed of steel. NYLON FUEL PIPES CAUTION: Refer to Fuel and EVAP Pipe Caution in Service Precautions. Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature. There are 3 sizes of nylon pipes used: 9.53 mm (3/8 in). ID for the fuel feed, 7.94 mm (5/16 inch). ID for the fuel return, and 12.7 mm (1/2 inch). ID for the vent. Heat resistant rubber hose or corrugated plastic conduit protect the sections of the pipes that are exposed to chafing, high temperature, or vibration. Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle. However, if nylon fuel pipes are forced into sharp bends, the pipes kink and restrict the fuel flow. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Take special care when working on a vehicle with nylon fuel pipes. FUEL PIPE O-RINGS O-rings seal the connections in the fuel system. Fuel system O-ring seals are made of special material. Service the O-ring seals with the correct service part. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Filter to Engine Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Filter to Engine FUEL HOSE/PIPES REPLACEMENT - FILTER TO ENGINE REMOVAL PROCEDURE CAUTION: In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. - When installing new fuel pipes, Do Not hammer directly on the fuel harness body clips as it may damage the nylon pipes resulting in a possible fuel leak. - Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. - Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.) - Refer to Battery Disconnect Caution in Service Precautions. NOTE: Refer to Cover and Plug Openings Notice in Service Precautions. IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Remove the cross vehicle brace. 2. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure. 3. Clean the engine fuel pipe connections. 4. Clean areas surrounding the engine fuel pipe connections. 5. Disconnect the fuel feed and fuel return pipe quick-connect fitting in the engine compartment. 6. Unclip and remove the fuel lines from the retainers. 7. Raise and support the vehicle. Refer to Vehicle Lifting. 8. Disconnect the fuel return and the EVAP pipe quick-connect fittings in front of the fuel tank. 9. Use a back-up wrench in order to prevent the in-line fuel filter from turning. Remove the threaded fitting nut from the outlet of the fuel filter. 10. Cap the in-pipe fuel filter pipe, the fuel feed pipe, and the fuel return pipe as needed to stop any fuel leakage. 11. Remove the fuel pipes and the EVAP pipe attaching hardware. 12. Note the position of the fuel and the EVAP pipes and the attaching hardware for installation. 13. Remove the fuel and the EVAP pipes from the vehicle. 14. Inspect the pipes for bends, kinks and cracks. 15. Repair or replace the pipe or pipes as necessary. INSTALLATION PROCEDURE CAUTION: In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, they must be replaced. NOTE: Refer to Fuel System Ground Notice in Service Precautions. - Secure the fuel pipes to the frame in order to prevent chafing. Maintain a minimum of 13 mm (1/2 inch) clearance around a pipe in order to prevent contact and chafing. Maintain a minimum of 19 mm (3/4 inch) around any moving part. - Do not allow the fuel pipes to come into contact with the fuel tank or underbody. IMPORTANT: If fuel line bundle attaching hardware is damaged or broken, replace the hardware. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Filter to Engine > Page 3918 1. Install the new fuel feed, the fuel return, and the EVAP pipes to the attaching hardware. 2. Install the fuel and the EVAP pipes, as noted during removal. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the fuel and the EVAP pipes retainers to the vehicle. Tighten Tighten the retainers to 10 N.m (89 lb in). 4. Remove the caps from the in-pipe fuel filter pipe, the fuel feed pipe, and the fuel return pipe. 5. Connect the fuel return and the EVAP pipes quick-connect fittings in front of the fuel tank. 6. Install the fuel feed pipe threaded fitting nut to the outlet of the fuel filter. Tighten Use a back-up wrench in order to prevent the in-line fuel filter from turning. Tighten the fuel filter outlet threaded fitting nut to 30 N.m (22 lb ft). 7. Lower the vehicle. 8. Connect the fuel and the EVAP pipes quick-connect fittings in the engine compartment. 9. Add fuel and Install the fuel tank filler pipe cap. 10. Lower the vehicle. 11. Connect the negative battery cable. 12. Inspect for leaks. 12.1. Turn ON the ignition for 2 seconds. 12.2. Turn OFF the ignition for 10 seconds. 12.3. Turn ON the ignition. 12.4. Inspect for fuel leaks. 13. Install the cross vehicle brace. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Filter to Engine > Page 3919 Fuel Supply Line: Service and Repair Fuel Hose/Pipes Replacement - Filter to Tank FUEL HOSES/PIPES REPLACEMENT - FILTER TO TANK REMOVAL PROCEDURE CAUTION: In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. - When installing new fuel pipes, Do Not hammer directly on the fuel harness body clips as it may damage the nylon pipes resulting in a possible fuel leak. - Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. - Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.) NOTE: Refer to Cover and Plug Openings Notice in Service Precautions. IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure. 2. Drain the fuel tank. Refer to Fuel Tank Draining Procedure. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the fuel tank. 5. Disconnect the fuel feed, the fuel return, and the evaporative emission (EVAP) pipe quick-connect fittings at the fuel sender assembly. 6. Cap the fuel sender fuel pipes and the in-pipe fuel filter pipes as needed to stop any fuel leakage. 7. Remove the fuel feed and the fuel return pipes from the fuel tank. Note the position of the pipes for installation. 8. Inspect the pipes for bends, kinks and cracks. 9. Repair or replace the pipe or pipes as necessary. INSTALLATION PROCEDURE CAUTION: In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, they must be replaced. NOTE: Refer to Fuel System Ground Notice in Service Precautions. - Secure the fuel pipes to the frame in order to prevent chafing. Maintain a minimum of 13 mm (1/2 inch) clearance around a pipe in order to prevent contact and chafing. Maintain a minimum of 19 mm (3/4 inch) around any moving part. - Do not allow the fuel pipes to come into contact with the fuel tank or underbody. 1. Install the new fuel feed and the fuel return pipes as noted during removal. 2. Remove the caps from the in-pipe fuel filter pipes and the fuel sender fuel pipes. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Service and Repair > Fuel Hose/Pipes Replacement - Filter to Engine > Page 3920 3. Connect the fuel feed, the fuel return, and the EVAP pipe quick-connect fittings at the fuel sender assembly. 4. Inspect the fuel pipe bundle clips, and the fasteners for proper installation. 5. Install the fuel tank. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Description and Operation Fuel Filler Hose: Description and Operation FUEL FILL PIPE The fuel fill pipe (2) has a built-in restrictor and deflector in order to prevent refueling with leaded fuel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Description and Operation > Page 3925 Fuel Filler Hose: Service and Repair FILLER TUBE REPLACEMENT REMOVAL PROCEDURE NOTE: Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages. IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Drain the fuel tank. Refer to Fuel Tank Draining Procedure. 2. Remove the fuel filler cap. 3. Remove the fuel filler pipe screws from the fuel filler pocket. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Loosen the fuel filler hose clamp (1) at the fuel filler pipe (2). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Description and Operation > Page 3926 6. Remove the fuel filler pipe screw from the under body. 7. Remove the fuel filler pipe. INSTALLATION PROCEDURE 1. Install the fuel filler pipe. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the fuel tank filler pipe screw to the under body. Tighten Tighten the screw to 13 N.m (115 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Filler Hose > Component Information > Description and Operation > Page 3927 3. Install the filler hose (4) to the fuel fill pipe (2).Inspect and ensure the filler hose (4) is fully seated on the fuel tank port and the fuel filler pipe (2). 4. Ensure the clamp (1) is properly located on the tank port between the bead (5) and the pipe (3). Tighten Tighten the fuel tank filler pipe hose clamp to 2.5 N.m (22 lb in). 5. Lower the vehicle. 6. Install the fuel filler pipe screws to the fuel filler pipe access panel. Tighten Tighten the screws to 2.5 N.m (22 lb in). 7. Add fuel and install the fuel fill cap. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications Fuel Gauge Sender: Specifications FUEL LEVEL SPECIFICATIONS The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 3931 Fuel Gauge Sender: Locations Fuel Pump And Sender Assembly Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 3932 Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 3933 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Specifications > Page 3934 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Remove the fuel sender assembly. 2. Disconnect the fuel level sensor electrical connector. 3. Remove the fuel level sensor (5) from the fuel sender assembly. INSTALLATION PROCEDURE 1. Install the fuel level sensor (5) to the fuel sender assembly. 2. Connect the fuel level sensor electrical connector. 3. Install the fuel sender assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 3938 Fuel Tank Unit: Description and Operation FUEL SENDER ASSEMBLY The fuel sender assembly consists of the following major components: - The fuel tank pressure (FTP) sensor (1) - The fuel tank fuel pump module (2) - The fuel strainer (3) - The fuel level sensor (4) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 3939 Fuel Tank Unit: Service and Repair FUEL SENDER ASSEMBLY REPLACEMENT REMOVAL PROCEDURE CAUTION: Fuel Vapors can collect while servicing fuel system parts in enclosed areas such as a trunk. To reduce the risk of fire and increased exposure to vapors: Use forced air ventilation such as a fan set outside of the trunk. - Plug or cap any fuel system openings in order to reduce fuel vapor formation. - Clean up any spilled fuel immediately. - Avoid sparks and any source of ignition. - Use signs to alert others in the work area that fuel system work is in process. NOTE: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system: The fuel pipe connections - The hose connections - The areas surrounding the connections IMPORTANT: For rear compartment (trunk) accessible fuel sender assemblies, completely remove the rear compartment carpet before removing the fuel sender access panel. - Always replace the fuel sender O-rings when reinstalling the fuel sender assembly. - The modular fuel sender assembly will spring-up when the snap ring is removed. - Always maintain cleanliness when servicing fuel system components. 1. Relieve the fuel system fuel pressure. Refer to Fuel Pressure Relief Procedure. 2. Remove the rear compartment trim panel. 3. Remove the fuel sender access panel nuts. 4. Remove the fuel sender access panel. 5. Disconnect the fuel tank pressure sensor electrical connector. 6. Disconnect the fuel sender electrical connector. 7. Clean the fuel pipes, and fuel sender assembly to prevent possible fuel contamination during removal. 8. Disconnect the quick-connect fittings at the fuel sender assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 3940 9. Remove the fuel sender retaining ring. 10. Remove the modular fuel sender assembly. 11. Clean the fuel sender assembly O-ring sealing surfaces. 12. Inspect the fuel sender assembly O-ring sealing surfaces. INSTALLATION PROCEDURE NOTE: Refer to Fuel System Ground Notice in Service Precautions. IMPORTANT: Care should be taken not to fold over or twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also, assure that the fuel pump strainer does not block full travel of float arm. - Ensure that the fuel sender assembly retaining snap ring is fully seated within the tab slots on the fuel tank. 1. Position the new fuel sender assembly O-ring on the fuel tank. 2. Install the fuel sender assembly into the fuel tank. 3. Install the fuel sender assembly retaining ring while holding the fuel sender assembly down. 4. Connect the fuel sender electrical connector. 5. Connect the fuel tank pressure sensor electrical connector. 6. Connect the quick-connect fittings at the fuel sender assembly. 7. Install the fuel filler cap. 8. Connect the negative battery cable. 9. Inspect for leaks. 9.1. Turn ON the ignition for 2 seconds. 9.2. Turn OFF the ignition for 10 seconds. 9.3. Turn ON the ignition. 9.4. Inspect for fuel leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank Unit > Component Information > Diagrams > Page 3941 10. Install the fuel sender access panel. NOTE: Refer to Fastener Notice in Service Precautions. 11. Install the fuel sender access panel nuts. Tighten Tighten the nuts to 10 N.m (89 lb in). 12. Install the rear compartment trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams Idle Air Control (IAC) Valve Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3945 Idle Speed/Throttle Actuator - Electronic: Testing and Inspection IDLE AIR CONTROL (IAC) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The engine idle speed is controlled by the idle air control (IAC) valve. The IAC valve is on the throttle body. The IAC valve pintle moves in and out of an idle air passage bore to control air flow around the throttle plate. The IAC valve consists of a movable pintle, driven by a gear attached to an electric motor called a stepper motor. The stepper motor is capable of highly accurate rotation, or of movement, called steps. The stepper motor has 2 separate windings that are called coils. Each coil is supplied current by two circuits from the powertrain control module (PCM). When the PCM changes polarity of a coil, the stepper motor moves one step. The PCM uses a predetermined number of counts to determine the IAC pintle position. Observe IAC counts with a scan tool. The IAC counts will increment up or down as the PCM attempts to change the IAC valve pintle position. An IAC Reset will occur when the ignition key is turned OFF. First, the PCM will seat the IAC pintle in the idle air passage bore. Second, the PCM will retract the pintle a predetermined number of counts to allow for efficient engine start-up. If the engine idle speed is out of range for a calibrated period of time, an idle speed diagnostic trouble code (DTC) sets. DIAGNOSTIC AIDS Inspect for the following conditions: High resistance in an IAC valve control circuit - The correct positive crankcase ventilation (PCV) valve, properly installed and proper operation of the PCV valve - Proper operation and installation of all air intake components - Proper installation and operation of the mass air flow (MAF) sensor, if equipped - A tampered with or damaged throttle stop screw - A tampered with or damaged throttle plate, throttle shaft, throttle linkage, or cruise control linkage, if equipped - A skewed high throttle position (TP) sensor - Excessive deposits in the IAC passage or on the IAC pintle - Excessive deposits in the throttle bore or on the throttle plate - Vacuum leaks - A high or unstable idle condition could be caused by a non-IAC system problem that can not be overcome by the IAC valve. Refer to Symptoms - Computers and Control Systems. See: Computers and Control Systems/Testing and Inspection/Symptom Related Diagnostic Procedures - If the problem is determined to be intermittent, refer to Intermittent Conditions. See: Computers and Control Systems/Testing and Inspection/Initial Inspection and Diagnostic Overview/Diagnostic Strategies TEST DESCRIPTION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3946 Steps 1-2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3947 Steps 3-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3948 Steps 6-8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3949 Steps 9-10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3950 Step 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3951 Steps 12-13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3952 Steps 14-19 The numbers below refer to the step numbers on the diagnostic table. 5. This test will determine the ability of the PCM and IAC valve control circuits to control the IAC valve. 7. This test will determine the ability of the PCM to provide the IAC control valve circuits with a ground. On a normally operating system, the test lamp should not flash while the IAC Counts are incrementing. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3953 Idle Speed/Throttle Actuator - Electronic: Service and Repair IDLE AIR CONTROL (IAC) VALVE REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Disconnect the idle air control valve (IAC) electrical connector. 3. Remove the IAC valve screws. 4. Remove the IAC valve. 5. Remove the IAC valve O-ring. INSTALLATION PROCEDURE NOTE: The IAC valve may be damaged if installed with the cone (pintle) extended more than 28 mm (1-1/8 in). Measure the distance that the valve is extended before installing a new valve. The distance from the idle air control valve motor housing to the end of the idle air control valve pintle Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3954 should be less than 28 mm (1-1/8 in). Manually compress the pintle until the extension is less than 28 mm (1-1/8 in). 1. Install the new IAC valve O-ring. 2. Install the IAC valve in the throttle body. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the IAC valve screws. Tighten Tighten the screws to 3 N.m (27 lb in). 4. Connect the IAC valve electrical connector. 5. The powertrain control module (PCM) will reset the IAC valve whenever the ignition is turned ON, then OFF. Turn ON the ignition for 10 seconds, then OFF for 5 seconds. 6. Start the engine and allow the engine to reach operating temperature. 7. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations Mass Air Flow (MAF) Sensor: Locations Left Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3959 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3960 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3961 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3962 Mass Air Flow (MAF) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Mass Air Flow (MAF) Sensor <--> [Air Flow Meter/Sensor] > Component Information > Locations > Page 3963 Mass Air Flow (MAF) Sensor: Service and Repair MASS AIR FLOW (MAF) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. IMPORTANT: The mass air flow (MAF) sensor is attached to the throttle body assembly. 2. Disconnect the MAF sensor electrical connector (8). 3. Remove the MAF sensor screws (9). 4. Remove the MAF sensor (1). INSTALLATION PROCEDURE 1. Install the MAF sensor (1). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the MAF sensor screws (9). Tighten Tighten the screws to 3 N.m (27 lb in). 3. Connect the MAF sensor electrical connector (8). 4. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set Throttle Position Sensor: Customer Interest Engine Controls - Intermittent Chuggle/No DTC's Set Bulletin No.: 05-06-04-058 Date: September 07, 2005 TECHNICAL Subject: Intermittent Chuggle or Fishbite on Light Acceleration or at Highway Speeds with No Diagnostic Trouble Codes (DTCs) (Replace Throttle Position ( TPS) Sensor) Models: 1995-1999 Buick Riviera 1995-2004 Buick Regal 1995-2005 Buick LeSabre, Park Avenue 1997-2005 Buick Century 1995-2001 Chevrolet Lumina 1995-2002 Chevrolet Camaro 1995-2005 Chevrolet Monte Carlo 2000-2005 Chevrolet Impala 1995-1997 Oldsmobile Cutlass Supreme, Ninety Eight 1995-1999 Oldsmobile Eighty Eight 1998-2002 Oldsmobile Intrigue 1995-2002 Pontiac Firebird 1995-2003 Pontiac Grand Prix 1995-2005 Pontiac Bonneville with 3800 V6 Engine (VIN K - RPO L36) Condition Some customers may comment on an intermittent chuggle or fishbite on light acceleration or at steady-state highway speeds (typically 80-105 km/h [50-65 mph]) with no PCM DTCs set. This condition may lead the technician to suspect the TCC circuit or torque converter. Cause This condition may be caused by intermittent operation of the Throttle Position (TPS) Sensor. Correction In observed cases, the Tech 2(R) is not fast enough to consistently detect this condition during a snapshot. It is recommended to use a DVOM set to the min/max recording mode. Connect the DVOM at the TPS connector (positive lead to TPS feedback signal pin and negative lead to TPS ground pin). Duplicate this condition by driving the vehicle. If the voltage dropout (less than 0.45 v) is recorded on the DVOM, replace the TPS sensor and re-evaluate the vehicle before continuing with other driveability or transmission diagnosis. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set > Page 3972 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set Throttle Position Sensor: All Technical Service Bulletins Engine Controls - Intermittent Chuggle/No DTC's Set Bulletin No.: 05-06-04-058 Date: September 07, 2005 TECHNICAL Subject: Intermittent Chuggle or Fishbite on Light Acceleration or at Highway Speeds with No Diagnostic Trouble Codes (DTCs) (Replace Throttle Position ( TPS) Sensor) Models: 1995-1999 Buick Riviera 1995-2004 Buick Regal 1995-2005 Buick LeSabre, Park Avenue 1997-2005 Buick Century 1995-2001 Chevrolet Lumina 1995-2002 Chevrolet Camaro 1995-2005 Chevrolet Monte Carlo 2000-2005 Chevrolet Impala 1995-1997 Oldsmobile Cutlass Supreme, Ninety Eight 1995-1999 Oldsmobile Eighty Eight 1998-2002 Oldsmobile Intrigue 1995-2002 Pontiac Firebird 1995-2003 Pontiac Grand Prix 1995-2005 Pontiac Bonneville with 3800 V6 Engine (VIN K - RPO L36) Condition Some customers may comment on an intermittent chuggle or fishbite on light acceleration or at steady-state highway speeds (typically 80-105 km/h [50-65 mph]) with no PCM DTCs set. This condition may lead the technician to suspect the TCC circuit or torque converter. Cause This condition may be caused by intermittent operation of the Throttle Position (TPS) Sensor. Correction In observed cases, the Tech 2(R) is not fast enough to consistently detect this condition during a snapshot. It is recommended to use a DVOM set to the min/max recording mode. Connect the DVOM at the TPS connector (positive lead to TPS feedback signal pin and negative lead to TPS ground pin). Duplicate this condition by driving the vehicle. If the voltage dropout (less than 0.45 v) is recorded on the DVOM, replace the TPS sensor and re-evaluate the vehicle before continuing with other driveability or transmission diagnosis. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Position Sensor: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set > Page 3978 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3979 Throttle Position Sensor: Locations Left Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3980 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3981 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3982 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3983 Throttle Position (TP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3984 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Remove the 2 TP sensor screws. 4. Remove the TP sensor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 3985 1. Install the TP sensor to the throttle body assembly. 2. Apply thread-locking compound GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the TP sensor screws. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 2 TP sensor screws. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Connect the TP sensor electrical connector. 5. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement Throttle Body: Service and Repair Throttle Body Assembly Replacement THROTTLE BODY ASSEMBLY REPLACEMENT REMOVAL PROCEDURE NOTE: Do not use solvent of any type when cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as damage to the gasket surfaces and throttle body assembly may result.Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly, as sharp tools may damage the gasket surfaces. 1. Remove the fuel injector sight shield. 2. Partially drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Remove the air cleaner intake duct. 4. Disconnect the idle air control (IAC) valve electrical connector. 5. Disconnect the mass air flow (MAF) sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 3990 6. Disconnect the throttle position (TP) sensor electrical connector. 7. Remove the accelerator controls cable bracket. 8. Disconnect the vacuum line from the throttle body. 9. Remove the exhaust crossover. 10. Remove the throttle body support bracket bolts. 11. Remove the throttle body support bracket. 12. Remove the throttle body nuts. 13. Remove the throttle body assembly. 14. Clean the gasket surface on the intake manifold and the throttle body assembly. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 3991 1. Install the new gasket. 2. Install the throttle body assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the throttle body nuts. Tighten Tighten the nuts to 10 N.m (89 lb in). 4. Install the throttle body support bracket. 5. Install the throttle body support bracket bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 6. Install the exhaust crossover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 3992 7. Connect the vacuum line to throttle body. 8. Install the accelerator controls cable bracket. 9. Connect the TP sensor electrical connector. 10. Connect the MAF sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 3993 11. Connect the IAC valve electrical connector. 12. Install the air cleaner intake duct. 13. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 14. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 3994 Throttle Body: Service and Repair Throttle Body Air Inlet Screen Replacement THROTTLE BODY AIR INLET SCREEN REPLACEMENT REMOVAL PROCEDURE 1. Remove the air cleaner intake duct. 2. Remove the snap ring (3). 3. Remove the throttle body air inlet screen (2). INSTALLATION PROCEDURE 1. Install the throttle body air inlet screen (2). 2. Install the snap ring (3). 3. Install the air cleaner intake duct. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Service and Repair > Throttle Body Assembly Replacement > Page 3995 Throttle Body: Service and Repair Throttle Body Cleaning Procedure THROTTLE BODY CLEANING PROCEDURE 1. Remove the air cleaner intake duct. 2. Remove the snap ring (3). 3. Remove the air inlet screen (2). 4. Inspect the throttle body bore and the throttle valve plate for deposits. You must open the throttle valve in order to inspect all of the surfaces. NOTE: Do not subject a throttle body assembly which contains the following components to an immersion cleaner or a strong solvent: Throttle position (TP) sensor - Idle air control (IAC) valve - Sealed throttle shaft bearings The cleaners will damage the electric components or sensors. The cleaners will damage some of these components that contain seals or O-rings. Solvents can wash away or break down the grease used on non-serviceable throttle shaft bearings. Never use a wire brush or scraper to clean the throttle body. A wire brush or sharp tools may damage the throttle body components. Do not use a cleaner that contains methyl ethyl ketone. This extremely strong solvent may damage components and is not necessary for this type of cleaning. 1. Clean the throttle body bore and the throttle valve plate using a clean shop towel with GM Top Engine Cleaner, P/N 1052626 (Canadian P/N 993026) or an equivalent product. 2. If the deposits are excessive, remove and disassemble the throttle body for cleaning. 3. After disassembly, clean the throttle body using a parts cleaning brush. DO NOT immerse the throttle body in any cleaning solvent. 4. If you removed and disassembled the throttle body for cleaning, assemble and install the throttle body. 5. Install the air inlet screen (2). 6. Install the snap ring (3). 7. Install the air cleaner intake duct. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement Throttle Cable/Linkage: Service and Repair Accelerator Controls Cable Replacement ACCELERATOR CONTROLS CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Remove the left instrument panel sound insulator. 3. Remove the accelerator cable (5) from the accelerator pedal (1). 4. Attach a piece of mechanics wire to aid in the installation of the new cable. 5. Squeeze the accelerator cable cover tangs and push the accelerator cable through the cowl. 6. Remove the accelerator cable from both retaining clips. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement > Page 4000 7. Remove the accelerator cable from the throttle body lever. 8. Remove the accelerator cable from the accelerator cable bracket. IMPORTANT: Note the routing of the accelerator cable for removal. 9. Remove the piece of mechanics wire from the cable. 10. Remove the accelerator cable from the vehicle. INSTALLATION PROCEDURE NOTE: Do not route flexible components (hoses, wires, conduits, etc.) within 50 mm (2 in) of moving parts unless flexible components can be securely fastened. This is necessary in order to prevent possible interference and damage to the component. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement > Page 4001 1. Attach the mechanics wire to the new cable. 2. Install the accelerator cable to vehicle using the routing verified during removal. 3. Install the accelerator cable through the cowl. 4. Remove the mechanics wire from the cable. 5. Install the accelerator cable (5) to the accelerator pedal lever (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement > Page 4002 6. Install the accelerator cable to the throttle body lever. 7. Install the accelerator cable to the accelerator cable bracket. 8. Install the accelerator cable to the retaining clips. 9. Inspect for complete throttle opening and closing positions by operating the accelerator pedal. Inspect for proper carpet fit under the accelerator pedal. 10. Install the left instrument panel sound insulator. 11. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement > Page 4003 Throttle Cable/Linkage: Service and Repair Accelerator Controls Cable Bracket Replacement ACCELERATOR CONTROLS CABLE BRACKET REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Remove the cruise control cable from the throttle body lever. 3. Remove the cruise control cable (1) from the bracket (2). 4. Remove accelerator cable from the throttle body lever. 5. Remove the accelerator cable (2) from the bracket (1). 6. Remove the accelerator controls cable bracket bolts. 7. Remove the accelerator controls cable bracket from the throttle body. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement > Page 4004 NOTE: Do not route flexible components (hoses, wires, conduits, etc.) within 50 mm (2 in) of moving parts unless flexible components can be securely fastened. This is necessary in order to prevent possible interference and damage to the component. 1. Install the accelerator controls cable bracket to the throttle body. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the accelerator controls cable bracket bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Install the accelerator cable (2) to the throttle body lever. 4. Install the accelerator cable (2) to the bracket (1). 5. Install the cruise control cable (1) to the bracket (2). 6. Install the cruise control cable to the throttle body lever. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Service and Repair > Accelerator Controls Cable Replacement > Page 4005 IMPORTANT: The throttle should operate freely, without binding, between full closed and wide open throttle. 7. Check for complete throttle opening and closing positions by operating the accelerator pedal. Also check for poor carpet fit under the accelerator pedal. 8. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-04-058 > Sep > 05 > Engine Controls Intermittent Chuggle/No DTC's Set Throttle Position Sensor: Customer Interest Engine Controls - Intermittent Chuggle/No DTC's Set Bulletin No.: 05-06-04-058 Date: September 07, 2005 TECHNICAL Subject: Intermittent Chuggle or Fishbite on Light Acceleration or at Highway Speeds with No Diagnostic Trouble Codes (DTCs) (Replace Throttle Position ( TPS) Sensor) Models: 1995-1999 Buick Riviera 1995-2004 Buick Regal 1995-2005 Buick LeSabre, Park Avenue 1997-2005 Buick Century 1995-2001 Chevrolet Lumina 1995-2002 Chevrolet Camaro 1995-2005 Chevrolet Monte Carlo 2000-2005 Chevrolet Impala 1995-1997 Oldsmobile Cutlass Supreme, Ninety Eight 1995-1999 Oldsmobile Eighty Eight 1998-2002 Oldsmobile Intrigue 1995-2002 Pontiac Firebird 1995-2003 Pontiac Grand Prix 1995-2005 Pontiac Bonneville with 3800 V6 Engine (VIN K - RPO L36) Condition Some customers may comment on an intermittent chuggle or fishbite on light acceleration or at steady-state highway speeds (typically 80-105 km/h [50-65 mph]) with no PCM DTCs set. This condition may lead the technician to suspect the TCC circuit or torque converter. Cause This condition may be caused by intermittent operation of the Throttle Position (TPS) Sensor. Correction In observed cases, the Tech 2(R) is not fast enough to consistently detect this condition during a snapshot. It is recommended to use a DVOM set to the min/max recording mode. Connect the DVOM at the TPS connector (positive lead to TPS feedback signal pin and negative lead to TPS ground pin). Duplicate this condition by driving the vehicle. If the voltage dropout (less than 0.45 v) is recorded on the DVOM, replace the TPS sensor and re-evaluate the vehicle before continuing with other driveability or transmission diagnosis. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Customer Interest: > 05-06-04-058 > Sep > 05 > Engine Controls Intermittent Chuggle/No DTC's Set > Page 4014 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set Throttle Position Sensor: All Technical Service Bulletins Engine Controls - Intermittent Chuggle/No DTC's Set Bulletin No.: 05-06-04-058 Date: September 07, 2005 TECHNICAL Subject: Intermittent Chuggle or Fishbite on Light Acceleration or at Highway Speeds with No Diagnostic Trouble Codes (DTCs) (Replace Throttle Position ( TPS) Sensor) Models: 1995-1999 Buick Riviera 1995-2004 Buick Regal 1995-2005 Buick LeSabre, Park Avenue 1997-2005 Buick Century 1995-2001 Chevrolet Lumina 1995-2002 Chevrolet Camaro 1995-2005 Chevrolet Monte Carlo 2000-2005 Chevrolet Impala 1995-1997 Oldsmobile Cutlass Supreme, Ninety Eight 1995-1999 Oldsmobile Eighty Eight 1998-2002 Oldsmobile Intrigue 1995-2002 Pontiac Firebird 1995-2003 Pontiac Grand Prix 1995-2005 Pontiac Bonneville with 3800 V6 Engine (VIN K - RPO L36) Condition Some customers may comment on an intermittent chuggle or fishbite on light acceleration or at steady-state highway speeds (typically 80-105 km/h [50-65 mph]) with no PCM DTCs set. This condition may lead the technician to suspect the TCC circuit or torque converter. Cause This condition may be caused by intermittent operation of the Throttle Position (TPS) Sensor. Correction In observed cases, the Tech 2(R) is not fast enough to consistently detect this condition during a snapshot. It is recommended to use a DVOM set to the min/max recording mode. Connect the DVOM at the TPS connector (positive lead to TPS feedback signal pin and negative lead to TPS ground pin). Duplicate this condition by driving the vehicle. If the voltage dropout (less than 0.45 v) is recorded on the DVOM, replace the TPS sensor and re-evaluate the vehicle before continuing with other driveability or transmission diagnosis. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 05-06-04-058 > Sep > 05 > Engine Controls - Intermittent Chuggle/No DTC's Set > Page 4020 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 4026 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: All Technical Service Bulletins Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Position Sensor: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 4036 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 4041 Throttle Position Sensor: Locations Left Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 4042 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 4043 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 4044 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 4045 Throttle Position (TP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 4046 Throttle Position Sensor: Service and Repair THROTTLE POSITION (TP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Disconnect the throttle position (TP) sensor electrical connector. 3. Remove the 2 TP sensor screws. 4. Remove the TP sensor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > Page 4047 1. Install the TP sensor to the throttle body assembly. 2. Apply thread-locking compound GM P/N 12345493 (Canadian P/N 10953488) or equivalent to the TP sensor screws. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the 2 TP sensor screws. Tighten Tighten the screws to 2 N.m (18 lb in). 4. Connect the TP sensor electrical connector. 5. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4052 Right Middle Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4053 Camshaft Position (CMP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4054 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The camshaft position (CMP) sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor does not directly affect the operation of the ignition system. The CMP sensor information is used by the powertrain control module (PCM) to determine the position of the valve train relative to the CKP. By monitoring the CMP and CKP signals the PCM can accurately time the operation of the fuel injectors. The CMP sensor shares 12-volt and low reference circuits with the CKP sensor. The CMP signal circuit is input to the ICM. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4055 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the coolant recovery reservoir. 2. Remove the drive belt. 3. Disconnect the electrical connector (2) from the camshaft position sensor (1). 4. Remove the camshaft position sensor bolt. 5. Remove the camshaft position sensor from the engine front cover. INSTALLATION PROCEDURE 1. Install the camshaft position sensor to the engine front cover. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4056 2. Install the camshaft position sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 3. Connect the electrical connector (2) to the camshaft position sensor (1). 4. Install the drive belt. 5. Install the coolant recovery reservoir. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4060 Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4061 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4062 Camshaft Position (CKP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4063 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSORS The crankshaft position (CKP) sensor has a 4-wire harness connector that plugs into the CKP sensor and connects to the ignition control module (ICM). The CKP sensor contains 2 hall-effect switches in 1 housing, and shares a magnet between the switches. The magnet and each hall-effect switch are separated by an air gap. A hall-effect switch is a solid state switching device that produces a digital ON/OFF pulse when a rotating element passes the sensor pick-up and interrupts the magnetic field of the sensor. The rotating element is called an interrupter ring or blade. There are two interrupter rings built into the crankshaft balancer. The outer ring and the outer switch provide the ICM with 18X signals or 18 identical pulses per crankshaft revolution. The inner ring and the inner switch provide the ICM with 3 pulses per revolution, each 1 of different duration. This is called the sync pulse. Each sync pulse represents a pair of companion cylinders. The ICM supplies a 12-volt and a low reference circuit to the CKP sensor, which is also shared by the camshaft position (CMP) sensor. The 18X reference pulses are passed from the CKP sensor to the ICM on the CKP sensor 1 signal circuit. The sync pulses are passed from the CKP sensor to the ICM on the CKP sensor 2 signal circuit. The ICM uses the 18X and sync pulses to determine the crankshaft position by counting how many ON-OFF 18X pulses occur during a sync pulse. With this dual interrupter ring arrangement the ICM can identify the correct pair of cylinders to fire within as little as 120 degrees of crankshaft rotation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4064 Crankshaft Position Sensor: Testing and Inspection CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The ignition control module (ICM) monitors the crankshaft position (CKP) sensor sync signal when the engine is cranking. The CKP sync signal is passed from the CKP sensor to the ICM on the CKP sensor 2 signal circuit. The CKP sync signal is used to determine the correct cylinder pair and initiate the ignition coil firing sequence. The 18X reference pulses are passed from the CKP sensor to the ICM on the CKP sensor 1 signal circuit. The 18X reference pulses are used for fuel injection and ignition control. After the ICM receives both signals, the ICM passes the 18X and 3X reference signals to the powertrain control module (PCM). The camshaft position sensor and the CKP sensor share a 12-volt reference and a low reference circuit. The CKP sensor consists of the following circuits: A 12-volt reference circuit - A low reference circuit - A CKP sensor 1 signal circuit - A CKP sensor 2 signal circuit TEST Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4065 Steps 4-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4066 Steps 8-14 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4067 Steps 15-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4068 Steps 21-26 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4069 Steps 27-28 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4070 Steps 29-31 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 4.1. Accelerate to wide open throttle (WOT). 4.2. Release throttle when fuel cut-off occurs. 4.3. Observe fuel cut-off specification for applicable engine. 4.4. Engine should not accelerate beyond calibrated RPM value. 4.5. Release throttle immediately if value is exceeded. 4.6. Block drive wheels. 4.7. Set parking brake. 4.8. DO NOT apply brake pedal. 4.9. Cycle ignition from OFF to ON. 4.10. Apply and hold brake pedal. 4.11. Start and idle engine. 4.12. Turn A/C OFF. 4.13. Vehicle must remain in Park or Neutral. 4.14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure.The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - Crankshaft position (CKP) sensors activity - If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity - If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool and perform the following: IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 5.1. Accelerate to WOT. 5.2. Release when fuel cut-off occurs. 5.3. Test in progress. 6. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 . If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC. 7. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set Engine replacement - PCM replacement - A harmonic balancer replacement - Crankshaft replacement - CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4073 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the right splash shield cover. 4. Remove the crankshaft balancer. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the CKP sensor shield (1). 7. Remove the CKP sensor bolts. 8. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4074 1. Position the CKP sensor to the block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolts. Tighten Tighten the bolts to 30 N.m (22 lb ft) 3. Install the CKP sensor shield (1). 4. Connect the CKP sensor electrical connector. 5. Install the crankshaft balancer. 6. Install the right splash shield cover. 7. Lower the vehicle. 8. Connect the negative battery cable. 9. Perform the Crankshaft Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection Ignition Cable: Testing and Inspection SPARK PLUG WIRE INSPECTION Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to accurately identify conditions that may affect engine operation. Refer to the list below for items to be inspected. 1. Inspect for correct routing of the spark plug wires. Improper routing may cause cross-firing. 2. Inspect each wire for any signs of cracks or splits in the wire. 3. Inspect each boot for the following conditions: - Tearing - Piercing - Arcing - Carbon tracking - Corroded terminal If corrosion, carbon tracking or arcing are indicated on a spark plug wire boot or terminal both the wire and the component connected to the wire should be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Page 4078 Ignition Cable: Service and Repair SPARK PLUG WIRE REPLACEMENT TOOLS REQUIRED J 38491 Spark Plug Boot Removal Tool REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Remove the spark plug wires (2, 4, 6) from the spark plugs at the rear of the engine using the following steps: 2.1. Note the position of the spark plug wires before removing the wires. 2.2. Twist the spark plug boot 1/2 turn before removing the boot. 2.3. Gently pry the heat shield up from spark plugs using the J 38491. 2.4. Remove the spark plug wire from the spark plugs at rear of the engine. 3. Remove the spark plug wires (1, 3, 5) from the spark plugs at the front of the engine using the following steps: 3.1. Note the position of the spark plug wires before removing the wires. 3.2. Twist the spark plug boot 1/2 turn before removing the boot. 3.3. Gently pry the heat shield up from spark plugs using the J 38491. 3.4. Remove the spark plug wires form the spark plugs at the front of the engine. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Page 4079 4. Remove the spark plug wires from the ignition coils. 5. Remove the spark plug wire retaining clips from the rear, front and top of the engine. 6. Remove the spark plug wires from the engine. 7. When replacing the spark plug wires transfer any of the following: - Boot heat shields - Spark plug wire conduit - Spark plug wire retaining clips INSTALLATION PROCEDURE 1. Position the spark plug wires to the engine. 2. Install the spark plug wire retaining clips from the rear, front and top of the engine. 3. Install the spark plug wires to the ignition coil in the proper position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Testing and Inspection > Page 4080 4. Install the spark plug wires (1, 3, 5) to the spark plugs in the proper position at the front of the engine. 5. Install the spark plug wires (2, 4, 6) to the spark plugs in the proper position at the rear of the engine. 6. Install the fuel injector sight shield. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation Ignition Coil: Description and Operation IGNITION CONTROL MODULE (ICM) AND IGNITION COILS Three dual tower ignition coils are mounted to the ICM, and are serviced individually. The ICM performs the following functions: - The ICM supplies a power and low reference circuit to the CMP and CKP sensors. - The ICM determines the correct direction of the crankshaft rotation, and cuts spark and fuel delivery to prevent damage from backfiring if reverse rotation is detected. - The ICM determines the correct coil triggering sequence, based on how many 18 X ON-OFF pulses occur during a sync pulse. This coil sequencing occurs at start-up, and is remembered by the ICM. After the engine is running, the ICM will continue to trigger the coils without the CKP sync pulse. - The ICM inputs 18 X and 3 X reference signals to the PCM. - The 3 X reference signal is also known as the low resolution engine speed signal. This signal is generated by the ICM using an internal divide-by-six circuit. This circuit divides the 18 X signal pulses by 6. This divider circuit will not begin operation without a sync pulse present at start-up, and without 18 X and 3 X reference signals no fuel injection will occur. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Description and Operation > Page 4084 Ignition Coil: Service and Repair IGNITION COIL(S) REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the spark plug wires from the ignition coil that is being serviced. 3. Remove the ignition coil screws (1). 4. Remove the coil (2) from the ignition control module (3). INSTALLATION PROCEDURE 1. Install the coil assembly (2) to the ignition control module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the ignition coil screws (1). Tighten Tighten the screws to 4.5 N.m (40 lb in). 3. Connect the spark plug wires to the ignition coil that is being serviced. 4. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 4088 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 4089 Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 4090 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 4091 Right Side Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 4092 Ignition Control Module: Diagrams Ignition Control Module (ICM) Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 4093 Ignition Control Module (ICM) Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 4094 Ignition Control Module: Description and Operation IGNITION CONTROL MODULE (ICM) AND IGNITION COILS Three dual tower ignition coils are mounted to the ICM, and are serviced individually. The ICM performs the following functions: - The ICM supplies a power and low reference circuit to the CMP and CKP sensors. - The ICM determines the correct direction of the crankshaft rotation, and cuts spark and fuel delivery to prevent damage from backfiring if reverse rotation is detected. - The ICM determines the correct coil triggering sequence, based on how many 18 X ON-OFF pulses occur during a sync pulse. This coil sequencing occurs at start-up, and is remembered by the ICM. After the engine is running, the ICM will continue to trigger the coils without the CKP sync pulse. - The ICM inputs 18 X and 3 X reference signals to the PCM. - The 3 X reference signal is also known as the low resolution engine speed signal. This signal is generated by the ICM using an internal divide-by-six circuit. This circuit divides the 18 X signal pulses by 6. This divider circuit will not begin operation without a sync pulse present at start-up, and without 18 X and 3 X reference signals no fuel injection will occur. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 4095 Ignition Control Module: Service and Repair IGNITION CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the 14-way electrical connector from the ignition control module (ICM). 3. Disconnect the spark plug wires from the coil assemblies. Before removing the wires, note the position of the wires. 4. Remove the ignition coil screws (1). 5. Remove the ignition coils (2) from the ICM (3). 6. Remove the ignition control module (3) from the bracket. INSTALLATION PROCEDURE 1. Install the ignition control module to the bracket. 2. Install the ignition coils (2) to the ignition control module (3). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the ignition coil screws (1). Tighten Tighten the screws to 4.5 N.m (40 lb in). 4. Connect the spark plug wires. 5. Connect the 14-way electrical connector to the module. Tighten Tighten the screw to 2.1 N.m (19 lb in). 6. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The ignition relay is a normally open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the run or start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by the relay coil, overcomes the spring tension and moves the armature allowing the relay contact to close. The closed relay contacts allow current to flow from the battery to the following fuses: Eng Devices - Oxy Sensors - DFI/MDL - Trans Sol - A/C Relay fuse - Fuel Inj When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the ignition relay fails to close, the engine will crank, but will not run. The class 2 communications will be available with the use of a scan tool. The ignition relay table assumes that the vehicle battery is fully charged. Refer to Battery Inspection/Test in Starting and Charging. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test TEST Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4099 Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4100 Steps 4-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4101 Step 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4102 Steps 7-9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4103 Steps 10-13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4104 Steps 14-16 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4105 Steps 17-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4106 Steps 21-22 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4107 Steps 23-25 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4108 Steps 26-34 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Lower Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4112 Rear Middle Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4113 Knock Sensor: Diagrams Knock Sensor (KS) 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4114 Knock Sensor (KS) 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4115 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This KS system uses one or two broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement Knock Sensor: Service and Repair Knock Sensor (KS) 1 Replacement KNOCK SENSOR (KS) 1 REPLACEMENT REMOVAL PROCEDURE CAUTION: Hot engine coolant may cause severe burns. Although the cooling system has been drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of the knock sensor. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Disconnect the knock sensor electrical connector (2). 4. Remove the knock sensor (1). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. 1. Install the knock sensor (1). Tighten Tighten the knock sensor to 19 N.m (14 lb ft). 2. Connect the knock sensor electrical connector (2). 3. Lower the vehicle. 4. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement > Page 4118 Knock Sensor: Service and Repair Knock Sensor (KS) 2 Replacement KNOCK SENSOR (KS) 2 REPLACEMENT REMOVAL PROCEDURE CAUTION: Hot engine coolant may cause severe burns. Although the cooling system has been drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of the knock sensor. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Remove the bolts (2) from the knock sensor heat shield (1). 4. Disconnect the knock sensor electrical connector (3) from the knock sensor. 5. Remove the knock sensor (4). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. 1. Install the knock sensor (4). Tighten Tighten the knock sensor to 19 N.m (14 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement > Page 4119 2. Install the knock sensor heat shield. Tighten Tighten the bolts to 60 N.m (44 lb ft). 3. Connect the knock sensor electrical connector. 4. Lower the vehicle. 5. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Ignition Control Module: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 4124 Upper Left Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 4125 Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 4126 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 4127 Right Side Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 4128 Ignition Control Module: Diagrams Ignition Control Module (ICM) Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 4129 Ignition Control Module (ICM) Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 4130 Ignition Control Module: Description and Operation IGNITION CONTROL MODULE (ICM) AND IGNITION COILS Three dual tower ignition coils are mounted to the ICM, and are serviced individually. The ICM performs the following functions: - The ICM supplies a power and low reference circuit to the CMP and CKP sensors. - The ICM determines the correct direction of the crankshaft rotation, and cuts spark and fuel delivery to prevent damage from backfiring if reverse rotation is detected. - The ICM determines the correct coil triggering sequence, based on how many 18 X ON-OFF pulses occur during a sync pulse. This coil sequencing occurs at start-up, and is remembered by the ICM. After the engine is running, the ICM will continue to trigger the coils without the CKP sync pulse. - The ICM inputs 18 X and 3 X reference signals to the PCM. - The 3 X reference signal is also known as the low resolution engine speed signal. This signal is generated by the ICM using an internal divide-by-six circuit. This circuit divides the 18 X signal pulses by 6. This divider circuit will not begin operation without a sync pulse present at start-up, and without 18 X and 3 X reference signals no fuel injection will occur. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 4131 Ignition Control Module: Service and Repair IGNITION CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the 14-way electrical connector from the ignition control module (ICM). 3. Disconnect the spark plug wires from the coil assemblies. Before removing the wires, note the position of the wires. 4. Remove the ignition coil screws (1). 5. Remove the ignition coils (2) from the ICM (3). 6. Remove the ignition control module (3) from the bracket. INSTALLATION PROCEDURE 1. Install the ignition control module to the bracket. 2. Install the ignition coils (2) to the ignition control module (3). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the ignition coil screws (1). Tighten Tighten the screws to 4.5 N.m (40 lb in). 4. Connect the spark plug wires. 5. Connect the 14-way electrical connector to the module. Tighten Tighten the screw to 2.1 N.m (19 lb in). 6. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection Ignition Relay: Testing and Inspection IGNITION RELAY DIAGNOSIS CIRCUIT DESCRIPTION The ignition relay is a normally open relay. The relay armature is held in the open position by spring tension. When the ignition switch is turned to the run or start position, current will flow through the relay coil. A wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by the relay coil, overcomes the spring tension and moves the armature allowing the relay contact to close. The closed relay contacts allow current to flow from the battery to the following fuses: Eng Devices - Oxy Sensors - DFI/MDL - Trans Sol - A/C Relay fuse - Fuel Inj When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses. If the ignition relay fails to close, the engine will crank, but will not run. The class 2 communications will be available with the use of a scan tool. The ignition relay table assumes that the vehicle battery is fully charged. Refer to Battery Inspection/Test in Starting and Charging. See: Starting and Charging/Testing and Inspection/Component Tests and General Diagnostics/Battery Inspection/Test TEST Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4135 Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4136 Steps 4-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4137 Step 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4138 Steps 7-9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4139 Steps 10-13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4140 Steps 14-16 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4141 Steps 17-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4142 Steps 21-22 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4143 Steps 23-25 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Relay > Component Information > Testing and Inspection > Page 4144 Steps 26-34 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations Camshaft Position Sensor: Locations Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4149 Right Middle Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4150 Camshaft Position (CMP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4151 Camshaft Position Sensor: Description and Operation CAMSHAFT POSITION (CMP) SENSOR The camshaft position (CMP) sensor signal is a digital ON/OFF pulse, output once per revolution of the camshaft. The CMP sensor does not directly affect the operation of the ignition system. The CMP sensor information is used by the powertrain control module (PCM) to determine the position of the valve train relative to the CKP. By monitoring the CMP and CKP signals the PCM can accurately time the operation of the fuel injectors. The CMP sensor shares 12-volt and low reference circuits with the CKP sensor. The CMP signal circuit is input to the ICM. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4152 Camshaft Position Sensor: Service and Repair CAMSHAFT POSITION (CMP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the coolant recovery reservoir. 2. Remove the drive belt. 3. Disconnect the electrical connector (2) from the camshaft position sensor (1). 4. Remove the camshaft position sensor bolt. 5. Remove the camshaft position sensor from the engine front cover. INSTALLATION PROCEDURE 1. Install the camshaft position sensor to the engine front cover. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Component Information > Locations > Page 4153 2. Install the camshaft position sensor bolt. Tighten Tighten the bolt to 10 N.m (89 lb in). 3. Connect the electrical connector (2) to the camshaft position sensor (1). 4. Install the drive belt. 5. Install the coolant recovery reservoir. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4157 Right Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4158 Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4159 Camshaft Position (CKP) Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4160 Crankshaft Position Sensor: Description and Operation CRANKSHAFT POSITION (CKP) SENSORS The crankshaft position (CKP) sensor has a 4-wire harness connector that plugs into the CKP sensor and connects to the ignition control module (ICM). The CKP sensor contains 2 hall-effect switches in 1 housing, and shares a magnet between the switches. The magnet and each hall-effect switch are separated by an air gap. A hall-effect switch is a solid state switching device that produces a digital ON/OFF pulse when a rotating element passes the sensor pick-up and interrupts the magnetic field of the sensor. The rotating element is called an interrupter ring or blade. There are two interrupter rings built into the crankshaft balancer. The outer ring and the outer switch provide the ICM with 18X signals or 18 identical pulses per crankshaft revolution. The inner ring and the inner switch provide the ICM with 3 pulses per revolution, each 1 of different duration. This is called the sync pulse. Each sync pulse represents a pair of companion cylinders. The ICM supplies a 12-volt and a low reference circuit to the CKP sensor, which is also shared by the camshaft position (CMP) sensor. The 18X reference pulses are passed from the CKP sensor to the ICM on the CKP sensor 1 signal circuit. The sync pulses are passed from the CKP sensor to the ICM on the CKP sensor 2 signal circuit. The ICM uses the 18X and sync pulses to determine the crankshaft position by counting how many ON-OFF 18X pulses occur during a sync pulse. With this dual interrupter ring arrangement the ICM can identify the correct pair of cylinders to fire within as little as 120 degrees of crankshaft rotation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4161 Crankshaft Position Sensor: Testing and Inspection CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS CIRCUIT DESCRIPTION The ignition control module (ICM) monitors the crankshaft position (CKP) sensor sync signal when the engine is cranking. The CKP sync signal is passed from the CKP sensor to the ICM on the CKP sensor 2 signal circuit. The CKP sync signal is used to determine the correct cylinder pair and initiate the ignition coil firing sequence. The 18X reference pulses are passed from the CKP sensor to the ICM on the CKP sensor 1 signal circuit. The 18X reference pulses are used for fuel injection and ignition control. After the ICM receives both signals, the ICM passes the 18X and 3X reference signals to the powertrain control module (PCM). The camshaft position sensor and the CKP sensor share a 12-volt reference and a low reference circuit. The CKP sensor consists of the following circuits: A 12-volt reference circuit - A low reference circuit - A CKP sensor 1 signal circuit - A CKP sensor 2 signal circuit TEST Steps 1-3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4162 Steps 4-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4163 Steps 8-14 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4164 Steps 15-20 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4165 Steps 21-26 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4166 Steps 27-28 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations > Page 4167 Steps 29-31 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure Crankshaft Position Sensor: Service and Repair CKP System Variation Learn Procedure CKP SYSTEM VARIATION LEARN PROCEDURE 1. Install a scan tool. 2. Monitor the powertrain control module for DTCs with a scan tool. If other DTCs are set, except DTC P0315, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC. 3. Select the crankshaft position variation learn procedure with a scan tool. 4. The scan tool instructs you to perform the following: 4.1. Accelerate to wide open throttle (WOT). 4.2. Release throttle when fuel cut-off occurs. 4.3. Observe fuel cut-off specification for applicable engine. 4.4. Engine should not accelerate beyond calibrated RPM value. 4.5. Release throttle immediately if value is exceeded. 4.6. Block drive wheels. 4.7. Set parking brake. 4.8. DO NOT apply brake pedal. 4.9. Cycle ignition from OFF to ON. 4.10. Apply and hold brake pedal. 4.11. Start and idle engine. 4.12. Turn A/C OFF. 4.13. Vehicle must remain in Park or Neutral. 4.14. The scan tool monitors certain component signals to determine if all the conditions are met to continue with the procedure.The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components: - Crankshaft position (CKP) sensors activity - If there is a CKP sensor condition, refer to the applicable DTC. - Camshaft position (CMP) signal activity - If there is a CMP signal condition, refer to the applicable DTC. - Engine coolant temperature (ECT) - If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the correct temperature. 5. Enable the crankshaft position system variation learn procedure with the scan tool and perform the following: IMPORTANT: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and the engine responds to throttle position after the learn procedure is complete. 5.1. Accelerate to WOT. 5.2. Release when fuel cut-off occurs. 5.3. Test in progress. 6. The scan tool displays Learn Status: Learned this ignition. If the scan tool indicates that DTC P0315 ran and passed, the CKP variation learn procedure is complete. If the scan tool indicates DTC P0315 failed or did not run, refer to DTC P0315 . If any other DTCs set, refer to Diagnostic Trouble Code (DTC) List for the applicable DTC. 7. Turn OFF the ignition for 30 seconds after the learn procedure is completed successfully. The CKP system variation learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set Engine replacement - PCM replacement - A harmonic balancer replacement - Crankshaft replacement - CKP sensor replacement - Any engine repairs which disturb the crankshaft to CKP sensor relationship. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4170 Crankshaft Position Sensor: Service and Repair Crankshaft Position (CKP) Sensor Replacement CRANKSHAFT POSITION (CKP) SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the right splash shield cover. 4. Remove the crankshaft balancer. 5. Disconnect the crankshaft position (CKP) sensor electrical connector. 6. Remove the CKP sensor shield (1). 7. Remove the CKP sensor bolts. 8. Remove the CKP sensor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Service and Repair > CKP System Variation Learn Procedure > Page 4171 1. Position the CKP sensor to the block. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the CKP sensor bolts. Tighten Tighten the bolts to 30 N.m (22 lb ft) 3. Install the CKP sensor shield (1). 4. Connect the CKP sensor electrical connector. 5. Install the crankshaft balancer. 6. Install the right splash shield cover. 7. Lower the vehicle. 8. Connect the negative battery cable. 9. Perform the Crankshaft Variation Learn Procedure. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder Replacement Removal Procedure Important: Perform the body control module (BCM) theft deterrent relearn procedure whenever you replace the ignition switch lock cylinder. 1. Disconnect the negative battery cable. 2. Remove the instrument panel (I/P) cluster trim plate. 3. Insert the key and turn the ignition lock cylinder to the ON/RUN position. 4. Using a small curved tool or an L-shaped hex wrench, depress and hold the detent on the ignition lock cylinder. Access the detent by placing the tool through the I/P opening to the right of the ignition switch. If you cannot locate the detent with the tool, lower the ignition switch away from the I/P. Refer to Ignition Switch Replacement. 5. Using the key as an aid, pull to remove the lock cylinder from the switch. 6. Remove the key from the lock cylinder. 7. If the cylinder does not rotate or is seized, follow the procedure in the ignition switch replacement. Refer to Ignition Switch Replacement. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 4176 1. Code the ignition lock cylinder, if necessary. Refer to Key and Lock Cylinder Coding in General Information. 2. Insert the key and turn the lock cylinder to the ON/RUN position. 3. Position the lock cylinder to the ignition switch. Press the cylinder into place. If you turned the key slightly while removing the lock cylinder, you may have to align the white colored ignition switch rotor (1) with the lock cylinder (2). You can rotate the ignition switch rotor (1) with your finger. 4. Turn the key to the OFF position and remove the key. 5. Install the I/P cluster trim plate. 6. Connect the negative battery cable. 7. If you installed a new lock cylinder, perform the BCM theft deterrent relearn procedure. Refer to Body Control Module (BCM) Programming/RPO Configuration in Body Control System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Lower Front Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4180 Rear Middle Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4181 Knock Sensor: Diagrams Knock Sensor (KS) 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4182 Knock Sensor (KS) 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4183 Knock Sensor: Description and Operation KNOCK SENSOR (KS) SYSTEM DESCRIPTION PURPOSE The knock sensor (KS) system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation. The control module uses the KS system to test for abnormal engine noise that may indicate detonation, also known as spark knock. SENSOR DESCRIPTION This KS system uses one or two broadband one-wire sensors. The sensor uses piezo-electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration, or noise, level. The amplitude and frequency are dependant upon the level of knock that the KS detects. The control module receives the KS signal through a signal circuit. The KS ground is supplied by the engine block through the sensor housing. One way the control module monitors the system is by output of a bias voltage on the KS signal wire. The bias voltage creates a voltage drop that the control module monitors and uses to help diagnose KS faults. The KS noise signal rides along this bias voltage, and due to the constantly fluctuating frequency and amplitude of the signal, will always be outside of the bias voltage parameters. Another way the control module monitors the system is by learning the average normal noise output from the KS. The control module learns a minimum noise level, or background noise, at idle from the KS and uses calibrated values for the rest of the RPM range. The control module uses the minimum noise level to calculate a noise channel. The control module uses this noise channel, and the KS signal that rides along the noise channel, in much the same way as the bias voltage type does. As engine speed and load change, the noise channel upper and lower parameters will change to accommodate the normal KS signal. In order to determine which cylinders are knocking, the control module only uses KS signal information when each cylinder is near top dead center (TDC) of the firing stroke. If the control module has determined that knock is present, it will retard the ignition timing to attempt to eliminate the knock. The control module will always try to work back to a zero compensation level, or no spark retard. An abnormal KS signal will fall within the noise channel or will not be present. KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module, the KS wiring, or the KS voltage output. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement Knock Sensor: Service and Repair Knock Sensor (KS) 1 Replacement KNOCK SENSOR (KS) 1 REPLACEMENT REMOVAL PROCEDURE CAUTION: Hot engine coolant may cause severe burns. Although the cooling system has been drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of the knock sensor. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Disconnect the knock sensor electrical connector (2). 4. Remove the knock sensor (1). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. 1. Install the knock sensor (1). Tighten Tighten the knock sensor to 19 N.m (14 lb ft). 2. Connect the knock sensor electrical connector (2). 3. Lower the vehicle. 4. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement > Page 4186 Knock Sensor: Service and Repair Knock Sensor (KS) 2 Replacement KNOCK SENSOR (KS) 2 REPLACEMENT REMOVAL PROCEDURE CAUTION: Hot engine coolant may cause severe burns. Although the cooling system has been drained, coolant still remains in the engine water jacket. This coolant will drain with the removal of the knock sensor. 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Remove the bolts (2) from the knock sensor heat shield (1). 4. Disconnect the knock sensor electrical connector (3) from the knock sensor. 5. Remove the knock sensor (4). INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: DO NOT apply thread sealant to sensor threads. The sensor is coated at factory and applying additional sealant will affect the sensors ability to detect detonation. 1. Install the knock sensor (4). Tighten Tighten the knock sensor to 19 N.m (14 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Service and Repair > Knock Sensor (KS) 1 Replacement > Page 4187 2. Install the knock sensor heat shield. Tighten Tighten the bolts to 60 N.m (44 lb ft). 3. Connect the knock sensor electrical connector. 4. Lower the vehicle. 5. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications Spark Plug Gap ................................................................................................................................... ..................................................... 0.060 in. (1.52 mm) Spark Plug Torque ........................................ ........................................................................................................................................ 11.0 lb. ft. (15.0 Nm) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4191 Spark Plug: Application and ID SPARK PLUG AC Delco P/N ...................................................................................................................................... .................................................................. 41-921 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4192 Spark Plug: Testing and Inspection SPARK PLUG INSPECTION SPARK PLUG USAGE - Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to Ignition System Specifications for the correct spark plug. - Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions: Spark plug fouling-Colder plug - Pre-ignition causing spark plug and/or engine damage-Hotter plug SPARK PLUG INSPECTION - Inspect the terminal post (1) for damage. Inspect for a bent or broken terminal post (1). - Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move. - Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post (1) and ground. Inspect for the following conditions: Inspect the spark plug boot for damage. - Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to ground. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4193 - Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4). - Inspect for evidence of improper arcing. Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications . An excessively wide electrode gap can prevent correct spark plug operation. - Inspect for the correct spark plug torque. Refer to Ignition System Specifications . Insufficient torque can prevent correct spark plug operation. An over torqued spark plug causes the insulator (2) to crack. - Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4). - Inspect for a broken or worn side electrode (3). - Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug. - A rattling sound indicates internal damage. - A loose center electrode (4) reduces the spark intensity. - Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap. - Inspect for worn or missing platinum pads on the electrodes (3, 4), if equipped. - Inspect for excessive fouling. - Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during installation. SPARK PLUG VISUAL INSPECTION - Normal operation-Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives. - Carbon fouled-Dry, fluffy black carbon, or soot caused by the following conditions: Rich fuel mixtures - Leaking fuel injectors - Excessive fuel pressure - Restricted air filter element Incorrect combustion - Reduced ignition system voltage output - Weak coils Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4194 - Worn ignition wires - Incorrect spark plug gap - Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off. - Deposit fouling-Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications > Page 4195 Spark Plug: Service and Repair SPARK PLUG REPLACEMENT REMOVAL PROCEDURE 1. Remove the spark plug wires from the spark plugs. 2. Remove the spark plugs from the engine. INSTALLATION PROCEDURE 1. Measure the spark plug gap on the spark plugs to be installed. Compare the measurement to the gap specifications. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the spark plugs to the engine. Tighten If installing the spark plugs to a new cylinder tighten the plugs to 27N.m (20 lb ft). - If installing the spark plugs to an existing cylinder tighten the plugs to 15N.m(11 lb ft). 1. Connect the spark plug wires to the spark plugs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4202 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4203 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid (PCS) Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the Pressure Control Solenoid (PCS) electrical connector. 3. Remove the PCS retaining clip (314E). 4. Remove the PCS (322). Installation Procedure 1. Install the PCS (322). 2. Install the PCS retaining clip (314E). 3. Connect the PCS electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Lower Center Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4207 Console And Center Of Floor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4208 A/T Shift Lock Control Solenoid Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift Shift Interlock Solenoid: Service and Repair With Floor Shift Automatic Transmission Shift Lock Actuator Replacement (Floor Shift) Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the center console. 3. Disconnect the automatic shift lock actuator electrical connector. 4. Remove the automatic shift lock actuator from the pivot point (1), the base of the shift lock control and the vehicle. Installation Procedure 1. Install the automatic shift lock actuator to the base of the shift lock control and the pivot point (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift > Page 4211 2. Connect the automatic shift lock actuator electrical connector. 3. Install the center console. 4. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift > Page 4212 Shift Interlock Solenoid: Service and Repair With Column Shift Automatic Transmission Shift Lock Actuator Replacement (Column Shift) Removal Procedure 1. Remove the knee bolster bracket. 2. Disconnect the automatic shift lock actuator electrical connector. 3. Remove the actuator from the steering column ball studs. Installation Procedure 1. Install the automatic shift lock control actuator to the steering column ball studs. 2. Connect the automatic shift lock actuator electrical connector. 3. Place the column in the neutral position. 4. Adjust the automatic shift lock actuator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift > Page 4213 4.1. Pull out the tab (1) on the adjuster block side (2) of the actuator. 4.2. Press on the adjuster block (2) in order to compress the internal adjuster spring and disengage the adjuster teeth. Slide the adjuster block as far away from the actuator as possible. 4.3./105GLock in place by pushing in on the tab (1). 5. Inspect the actuator ^ The actuator must lock the shift lever clevis when you place the clevis in the park position. ^ If you can move the shift lever without pressing on the brake pedal. readjust the actuator. 6. Install the knee bolster bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid Valve State and Gear Ratio Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4217 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid Valve Connector, Wiring Harness Side > Page 4220 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the 1-2 shift solenoid electrical connector. 3. Remove the 1-2 shift solenoid retaining clip (314D) 4. Remove the 1-2 shift solenoid (315A). Installation Procedure 1. Install the 1-2 shift solenoid (315A). 2. Install the 1-2 shift solenoid retaining clip (314D). 3. Connect the 1-2 shift solenoid electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 4223 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the 2-3 shift solenoid electrical connector. 3. Remove the 2-3 shift solenoid retaining clip (314C). 4. Remove the 2-3 shift solenoid (315B) and the O-ring (316). Installation Procedure 1. Install the O-ring (316) and the 2-3 shift solenoid (315B). 2. Install the 2-3 shift solenoid retaining clip (314C). 3. Connect the 2-3 shift solenoid electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 4227 Torque Converter Clutch Pulse Width Modulated Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch (TCC) Solenoid Torque Converter Clutch (TCC) Solenoid Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Remove the TCC solenoid retaining clip (314) 4. Remove the TCC solenoid (315). Installation Procedure 1. install the TCC solenoid (315). 2. Install the TCC solenoid retaining clip (314). 3. Connect the TCC solenoid electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 4230 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect and reposition the electrical connectors from the following: ^ If equipped internal mode switch ^ 2 - 3 Shift solenoid valve assembly (315B) ^ Automatic transaxle fluid pressure manual valve position switch assembly (395) Important: Do NOT remove the bolt (205) that holds the oil pump together. 3. Remove the oil pump bolts (206, 207). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 4231 4. Remove the oil pump (200) from the valve body (300). 5. Disconnect the Torque Converter Clutch Pulse Width Modulation (TCC PWM) solenoid electrical connector. 6. Remove the TCC PWM solenoid retaining clip (314F). 7. Remove the TCC PWM solenoid (334). Installation Procedure 1. Install the TCC PWM solenoid (334). 2. Install the TCC PWM solenoid retaining clip (314F). 3. Connect the TCC PWM solenoid electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 4232 4. Install the oil pump (200) to the valve body (300). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pump bolts (206, 207). Tighten ^ Tighten the bolts (207) to 12 Nm (106 inch lbs.). ^ Tighten the bolts (206) to 16 Nm (12 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 4233 6. Reposition and connect the electrical connectors to the following: ^ Automatic transaxle fluid pressure manual valve position switch assembly (395) ^ 2 - 3 Shift solenoid valve assembly (315B) ^ If equipped internal mode switch 7. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Diagrams PRNDL Lamp Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams TCC Brake Switch Wiring Harness Side C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4250 Automatic Transmission Fluid Pressure Manual Valve Position Switch Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4251 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the transaxle wiring harness. 3. Remove the control valve body bolts (375, 379, 381) that mount the fluid pressure manual valve position switch to the control valve body (300). Important: When removing the TFP switch handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 4. Carefully remove the fluid pressure manual valve position switch (395) 5. Inspect the fluid pressure manual valve position switch (395) for the following conditions ^ Damaged electrical connector terminals ^ Damaged seals ^ Damaged switch membranes ^ Debris on the switch membranes Installation Procedure Important: When installing the TFP switch handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 1. Carefully install the fluid pressure manual valve position switch (395). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the control valve body bolts (375, 379, 381) that mount the TFP switch to the control valve body (300). ^ Tighten the control valve body bolt (375) to 12 Nm (106 inch lbs.). ^ Tighten the control valve body bolt (379) to 16 Nm (106 inch lbs.). ^ Tighten the control valve body bolt (381) to 8 Nm (70 inch lbs.). 3. Connect the transaxle wiring harness. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4252 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4256 Input Speed Sensor Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4257 Transmission Speed Sensor: Service and Repair Input Speed Sensor Replacement Removal Procedure 1. Remove the case side cover 2. Disconnect the input speed sensor electrical connector. 3. Remove the input speed sensor retaining clip (441). 4. Remove the input speed sensor (440). 5. Inspect the input speed sensor (440) for the following conditions: ^ Damaged or missing magnet ^ Damaged housing ^ Bent or missing electrical terminals ^ Damaged speed sensor clip (441) Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4258 1. Install the input speed sensor (440). 2. Install the input speed sensor retaining clip (441). 3. Connect the input speed sensor electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 4262 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 4263 Transmission Fluid Temperature Sensor Connector Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement Transmission Temperature Sensor/Switch: Service and Repair Thermo Element Replacement Thermo Element Replacement Tools Required ^ J 34094-A Thermo Element Height Gage Removal Procedure 1. Raise and support the vehicle. 2. Remove the oil pan. 3. Remove the thermo element pins (120, 123) and the washers. 4. Remove the thermo element (121) and the thermo element plate (122). Installation Procedure 1. Use the J 34094-A to set the middle thermo pin (123). 2. Install the new thermo element plate (122). 3. Install the pin (120) and the washer. 4. Use the J 34094-A to set the height of the pin and the washer furthest from the accumulator. 5. Use the J 34094-A to set the height of the second pin (120) and the washer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement > Page 4266 6. Install the thermo element (121) between the two pins (120). The V in the thermo element (121) must contact the thermo element plate (122). 7. Install the oil pan. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement > Page 4267 Transmission Temperature Sensor/Switch: Service and Repair Fluid Temperature Sensor Replacement Fluid Temperature Sensor Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the wiring harness assembly tram the fluid temperature sensor (391) 3. Remove the fluid temperature sensor (391). Installation Procedure 1. install the fluid temperature sensor (391). 2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 04-06-04-066B > Sep > 05 > Engine Controls/Fuel - Clunk/Bang From Vehicle Rear PROM - Programmable Read Only Memory: Customer Interest Engine Controls/Fuel - Clunk/Bang From Vehicle Rear Bulletin No.: 04-06-04-066B Date: September 02, 2005 TECHNICAL Subject: Clunk/Bang From Rear of Vehicle (Replace Fuel Tank and Reflash PCM) Models: 2003-2004 Buick Century, Regal 2003-2004 Chevrolet Impala, Monte Carlo 2004 Pontiac Grand Prix Supercede: This bulletin is being revised to remove the 2003 Grand Prix from the models. Please discard Corporate Bulletin Number 04-06-04-066A (Section 06 - Engine/Propulsion System). Condition Some customers may comment on a clunk/bang type noise coming from the rear of the vehicle. This noise will be most noticeable when the vehicle comes to a stop or during parking lot maneuvers. Customers may also comment that the noise occurs when the fuel tank is between 1/2 and full. Cause The noise may be caused by fuel sloshing around in the fuel tank. Correction Replace the fuel tank with P/N 15141578. Refer to the Fuel Tank Replacement procedure in the Engine Controls sub-section of the service manual. This new tank has internal baffles to prevent the fuel from sloshing around. Important: This new fuel tank also requires the PCM to be reflashed with a new service calibration due to revised evaporative characteristics. This new calibration is currently available through TIS2000. As always, make sure your Tech 2(R) is updated with the latest software version. You will need to call Techline(R) Customer Support Center (TCSC). TCSC will provide a VCI number to allow the vehicle to be updated with the proper calibration. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > Customer Interest for PROM - Programmable Read Only Memory: > 04-06-04-066B > Sep > 05 > Engine Controls/Fuel - Clunk/Bang From Vehicle Rear > Page 4276 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-06-04-066B > Sep > 05 > Engine Controls/Fuel - Clunk/Bang From Vehicle Rear PROM - Programmable Read Only Memory: All Technical Service Bulletins Engine Controls/Fuel Clunk/Bang From Vehicle Rear Bulletin No.: 04-06-04-066B Date: September 02, 2005 TECHNICAL Subject: Clunk/Bang From Rear of Vehicle (Replace Fuel Tank and Reflash PCM) Models: 2003-2004 Buick Century, Regal 2003-2004 Chevrolet Impala, Monte Carlo 2004 Pontiac Grand Prix Supercede: This bulletin is being revised to remove the 2003 Grand Prix from the models. Please discard Corporate Bulletin Number 04-06-04-066A (Section 06 - Engine/Propulsion System). Condition Some customers may comment on a clunk/bang type noise coming from the rear of the vehicle. This noise will be most noticeable when the vehicle comes to a stop or during parking lot maneuvers. Customers may also comment that the noise occurs when the fuel tank is between 1/2 and full. Cause The noise may be caused by fuel sloshing around in the fuel tank. Correction Replace the fuel tank with P/N 15141578. Refer to the Fuel Tank Replacement procedure in the Engine Controls sub-section of the service manual. This new tank has internal baffles to prevent the fuel from sloshing around. Important: This new fuel tank also requires the PCM to be reflashed with a new service calibration due to revised evaporative characteristics. This new calibration is currently available through TIS2000. As always, make sure your Tech 2(R) is updated with the latest software version. You will need to call Techline(R) Customer Support Center (TCSC). TCSC will provide a VCI number to allow the vehicle to be updated with the proper calibration. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: > 04-06-04-066B > Sep > 05 > Engine Controls/Fuel - Clunk/Bang From Vehicle Rear > Page 4282 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4289 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4290 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid (PCS) Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the Pressure Control Solenoid (PCS) electrical connector. 3. Remove the PCS retaining clip (314E). 4. Remove the PCS (322). Installation Procedure 1. Install the PCS (322). 2. Install the PCS retaining clip (314E). 3. Connect the PCS electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Lower Center Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4294 Console And Center Of Floor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4295 A/T Shift Lock Control Solenoid Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift Shift Interlock Solenoid: Service and Repair With Floor Shift Automatic Transmission Shift Lock Actuator Replacement (Floor Shift) Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the center console. 3. Disconnect the automatic shift lock actuator electrical connector. 4. Remove the automatic shift lock actuator from the pivot point (1), the base of the shift lock control and the vehicle. Installation Procedure 1. Install the automatic shift lock actuator to the base of the shift lock control and the pivot point (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift > Page 4298 2. Connect the automatic shift lock actuator electrical connector. 3. Install the center console. 4. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift > Page 4299 Shift Interlock Solenoid: Service and Repair With Column Shift Automatic Transmission Shift Lock Actuator Replacement (Column Shift) Removal Procedure 1. Remove the knee bolster bracket. 2. Disconnect the automatic shift lock actuator electrical connector. 3. Remove the actuator from the steering column ball studs. Installation Procedure 1. Install the automatic shift lock control actuator to the steering column ball studs. 2. Connect the automatic shift lock actuator electrical connector. 3. Place the column in the neutral position. 4. Adjust the automatic shift lock actuator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift > Page 4300 4.1. Pull out the tab (1) on the adjuster block side (2) of the actuator. 4.2. Press on the adjuster block (2) in order to compress the internal adjuster spring and disengage the adjuster teeth. Slide the adjuster block as far away from the actuator as possible. 4.3./105GLock in place by pushing in on the tab (1). 5. Inspect the actuator ^ The actuator must lock the shift lever clevis when you place the clevis in the park position. ^ If you can move the shift lever without pressing on the brake pedal. readjust the actuator. 6. Install the knee bolster bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid Valve State and Gear Ratio Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4304 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid Valve Connector, Wiring Harness Side > Page 4307 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the 1-2 shift solenoid electrical connector. 3. Remove the 1-2 shift solenoid retaining clip (314D) 4. Remove the 1-2 shift solenoid (315A). Installation Procedure 1. Install the 1-2 shift solenoid (315A). 2. Install the 1-2 shift solenoid retaining clip (314D). 3. Connect the 1-2 shift solenoid electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 4310 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the 2-3 shift solenoid electrical connector. 3. Remove the 2-3 shift solenoid retaining clip (314C). 4. Remove the 2-3 shift solenoid (315B) and the O-ring (316). Installation Procedure 1. Install the O-ring (316) and the 2-3 shift solenoid (315B). 2. Install the 2-3 shift solenoid retaining clip (314C). 3. Connect the 2-3 shift solenoid electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 4314 Torque Converter Clutch Pulse Width Modulated Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch (TCC) Solenoid Torque Converter Clutch (TCC) Solenoid Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Remove the TCC solenoid retaining clip (314) 4. Remove the TCC solenoid (315). Installation Procedure 1. install the TCC solenoid (315). 2. Install the TCC solenoid retaining clip (314). 3. Connect the TCC solenoid electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 4317 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect and reposition the electrical connectors from the following: ^ If equipped internal mode switch ^ 2 - 3 Shift solenoid valve assembly (315B) ^ Automatic transaxle fluid pressure manual valve position switch assembly (395) Important: Do NOT remove the bolt (205) that holds the oil pump together. 3. Remove the oil pump bolts (206, 207). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 4318 4. Remove the oil pump (200) from the valve body (300). 5. Disconnect the Torque Converter Clutch Pulse Width Modulation (TCC PWM) solenoid electrical connector. 6. Remove the TCC PWM solenoid retaining clip (314F). 7. Remove the TCC PWM solenoid (334). Installation Procedure 1. Install the TCC PWM solenoid (334). 2. Install the TCC PWM solenoid retaining clip (314F). 3. Connect the TCC PWM solenoid electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 4319 4. Install the oil pump (200) to the valve body (300). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pump bolts (206, 207). Tighten ^ Tighten the bolts (207) to 12 Nm (106 inch lbs.). ^ Tighten the bolts (206) to 16 Nm (12 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 4320 6. Reposition and connect the electrical connectors to the following: ^ Automatic transaxle fluid pressure manual valve position switch assembly (395) ^ 2 - 3 Shift solenoid valve assembly (315B) ^ If equipped internal mode switch 7. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4326 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4327 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid (PCS) Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the Pressure Control Solenoid (PCS) electrical connector. 3. Remove the PCS retaining clip (314E). 4. Remove the PCS (322). Installation Procedure 1. Install the PCS (322). 2. Install the PCS retaining clip (314E). 3. Connect the PCS electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Lower Center Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4331 Console And Center Of Floor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4332 A/T Shift Lock Control Solenoid Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift Shift Interlock Solenoid: Service and Repair With Floor Shift Automatic Transmission Shift Lock Actuator Replacement (Floor Shift) Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the center console. 3. Disconnect the automatic shift lock actuator electrical connector. 4. Remove the automatic shift lock actuator from the pivot point (1), the base of the shift lock control and the vehicle. Installation Procedure 1. Install the automatic shift lock actuator to the base of the shift lock control and the pivot point (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift > Page 4335 2. Connect the automatic shift lock actuator electrical connector. 3. Install the center console. 4. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift > Page 4336 Shift Interlock Solenoid: Service and Repair With Column Shift Automatic Transmission Shift Lock Actuator Replacement (Column Shift) Removal Procedure 1. Remove the knee bolster bracket. 2. Disconnect the automatic shift lock actuator electrical connector. 3. Remove the actuator from the steering column ball studs. Installation Procedure 1. Install the automatic shift lock control actuator to the steering column ball studs. 2. Connect the automatic shift lock actuator electrical connector. 3. Place the column in the neutral position. 4. Adjust the automatic shift lock actuator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift > Page 4337 4.1. Pull out the tab (1) on the adjuster block side (2) of the actuator. 4.2. Press on the adjuster block (2) in order to compress the internal adjuster spring and disengage the adjuster teeth. Slide the adjuster block as far away from the actuator as possible. 4.3./105GLock in place by pushing in on the tab (1). 5. Inspect the actuator ^ The actuator must lock the shift lever clevis when you place the clevis in the park position. ^ If you can move the shift lever without pressing on the brake pedal. readjust the actuator. 6. Install the knee bolster bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid Valve State and Gear Ratio Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 4341 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid Valve Connector, Wiring Harness Side > Page 4344 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the 1-2 shift solenoid electrical connector. 3. Remove the 1-2 shift solenoid retaining clip (314D) 4. Remove the 1-2 shift solenoid (315A). Installation Procedure 1. Install the 1-2 shift solenoid (315A). 2. Install the 1-2 shift solenoid retaining clip (314D). 3. Connect the 1-2 shift solenoid electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 4347 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the 2-3 shift solenoid electrical connector. 3. Remove the 2-3 shift solenoid retaining clip (314C). 4. Remove the 2-3 shift solenoid (315B) and the O-ring (316). Installation Procedure 1. Install the O-ring (316) and the 2-3 shift solenoid (315B). 2. Install the 2-3 shift solenoid retaining clip (314C). 3. Connect the 2-3 shift solenoid electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 4351 Torque Converter Clutch Pulse Width Modulated Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch (TCC) Solenoid Torque Converter Clutch (TCC) Solenoid Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Remove the TCC solenoid retaining clip (314) 4. Remove the TCC solenoid (315). Installation Procedure 1. install the TCC solenoid (315). 2. Install the TCC solenoid retaining clip (314). 3. Connect the TCC solenoid electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 4354 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect and reposition the electrical connectors from the following: ^ If equipped internal mode switch ^ 2 - 3 Shift solenoid valve assembly (315B) ^ Automatic transaxle fluid pressure manual valve position switch assembly (395) Important: Do NOT remove the bolt (205) that holds the oil pump together. 3. Remove the oil pump bolts (206, 207). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 4355 4. Remove the oil pump (200) from the valve body (300). 5. Disconnect the Torque Converter Clutch Pulse Width Modulation (TCC PWM) solenoid electrical connector. 6. Remove the TCC PWM solenoid retaining clip (314F). 7. Remove the TCC PWM solenoid (334). Installation Procedure 1. Install the TCC PWM solenoid (334). 2. Install the TCC PWM solenoid retaining clip (314F). 3. Connect the TCC PWM solenoid electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 4356 4. Install the oil pump (200) to the valve body (300). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pump bolts (206, 207). Tighten ^ Tighten the bolts (207) to 12 Nm (106 inch lbs.). ^ Tighten the bolts (206) to 16 Nm (12 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 4357 6. Reposition and connect the electrical connectors to the following: ^ Automatic transaxle fluid pressure manual valve position switch assembly (395) ^ 2 - 3 Shift solenoid valve assembly (315B) ^ If equipped internal mode switch 7. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair Accumulator: Service and Repair Accumulator and 2-1 Manual Servo Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the filter. 3. Remove the accumulator bolts (131). 4. Remove the manual 2-1 band servo cover bolts (103). 5. Remove the accumulator assembly. 6. Remove the manual 2-1 band servo (106-116). 7. To disassemble, inspect and service the accumulator and 2 - 1 manual servo. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 4361 Installation Procedure 1. If disassembled, assemble the 2-1 band servo. 2. Install the manual 2-1 band servo (106-116). 3. Install the accumulator assembly. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the manual 2-1 band servo cover bolts (103). Tighten the bolts to 25 Nm (18 ft. lbs.). 5. Install the accumulator bolts (131). Tighten the bolts to 12 Nm (106 inch lbs.). 6. Install the filter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > Page 4362 7. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: Customer Interest A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 4371 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Band Apply Servo: Customer Interest A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4376 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4377 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E Fluid Leaks From Reverse Servo Cover Bulletin No.: 04-07-30-028A Date: January 12, 2006 TECHNICAL Subject: 4T65-E Automatic Transmission Fluid Leak From Reverse Servo Cover (Replace Reverse Servo Cover Seal) Models: 2005 and Prior Cars and Light Duty Trucks with Automatic Transmission 4T65-E (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to announce an improved reverse servo cover seal is available from GMSPO and to advise technicians that it is no longer necessary to replace the reverse servo cover when replacing the seal. The 2005 model year vehicles are also being added. Please discard Corporate Bulletin Number 04-07-30-028 (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a fluid leak under the vehicle. A transmission fluid leak may be noted during the Pre-delivery Inspection (PDI). Cause A possible cause of a transmission fluid leak usually only during cold ambient temperatures below -6.7°C (20°F) may be the reverse servo cover seal. The reverse servo cover seal may shrink in cold ambient temperatures causing a transmission fluid leak. Correction Follow the diagnosis and repair procedure below to correct this condition. 1. Diagnose the source of the fluid leak. 2. If the source of the transmission fluid leak is the reverse servo cover, replace the reverse servo cover seal with P/N 24235894. Refer to Reverse Servo Replacement in the appropriate Service Manual. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-028A > Jan > 06 > A/T - 4T65-E Fluid Leaks From Reverse Servo Cover > Page 4383 3. Clean the area around and below the cover. 4. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in the appropriate Service Manual. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Band Apply Servo: All Technical Service Bulletins A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4388 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band Apply Servo: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4389 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Replacement Band Apply Servo: Service and Repair Reverse Servo Replacement Reverse Servo Replacement Removal Procedure 1. Remove the air cleaner intake duct. 2. Depress the reverse servo cover (40). 3. Remove the snap ring (39). 4. Pull the O-ring seal (41) out through the slot in the case. 5. Use side cutting pliers in order to cut the servo cover O-ring seal (41). 6. Depress the reverse servo cover (40), grasp one end of the cut seal (41) and pull the seal (41) out of the servo cover (40). 7. Remove the reverse servo cover (40). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Replacement > Page 4392 8. Remove the servo assembly (4208). 9. Remove the servo spring (49). Installation Procedure Important: Follow this procedure exactly or the transaxle will have no reverse gear due to the servo pin missing the band. 1. Jack up the driver side of the car until the driver side is higher than the differential side. This ensures that the reverse band is in the proper location and not cocked to the channel plate side of the case. 2. Install the servo spring (49). 3. Install the servo assembly (42-48). 4. Install the reverse servo cover (40) with the new O-ring seal (41). 5. Compress the servo cover (40) and install the snap ring (39). 6. Install the air cleaner intake duct. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Replacement > Page 4393 Band Apply Servo: Service and Repair Forward Servo Replacement Forward Servo Replacement Removal Procedure 1. Install the engine support fixture. 2. Raise and support the vehicle. 3. Remove and support the power steering gear. 4. Remove the transaxle mount lower nuts. 5. Remove the engine mount lower nuts. 6. Remove the power steering lines from the right side of the frame. 7. Support the rear of the frame with a jackstand. 8. Loosen the front frame bolts and remove the rear frame bolts. 9. Adjust the jackstand to lower the rear of the frame. 10. Position a drain pan under the forward servo cover. 11. Remove the servo cover bolts. 12. Remove the forward servo cover. 13. Remove the forward servo cover O-ring. 14. Remove the servo piston assembly. 15. Remove the servo spring. Installation Procedure 1. Install the spring. 2. Install the piston assembly. 3. install the O-ring. 4. Install the servo cover. Notice: Refer to Fastener Notice in Service precautions. 5. Install the servo cover bolts. Tighten the bolts to 12 Nm (106 inch lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Reverse Servo Replacement > Page 4394 6. Remove the drain pan from under the forward servo cover. 7. Adjust the jackstand in order to raise the rear of the frame. 8. Install the frame bolts. 9. Remove the support from the rear of the frame. 10. Install the power steering lines to the right side of the frame. 11. Install the engine mount lower nuts. 12. Install the transaxle mount lower nuts. 13. Install the power steering gear. 14. Lower the vehicle. 15. Remove the engine support fixture. Notice: Refer to Do Not Overfill the Transmission Notice. 16. Check and fill the transaxle as necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Brake Switch - TCC > Component Information > Diagrams TCC Brake Switch Wiring Harness Side C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Case: Customer Interest A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Incorrect Transmission Shifts, Poor Engine Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck Off/On, DTCs P0757, P0741, P0742, P0730, P0756 # 02-07-30-013E - (May 20, 2005) Models: 2001-2005 GM Passenger Cars with 4T65-E Automatic Transmission 2001-2005 Buick Rendezvous 2005 Buick Terraza 2001-2004 Chevrolet Venture 2005 Chevrolet Uplander 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Montana 2005 Saturn Relay with 4T65-F Transmission (RPOs M15, MN3, MN7, M76) This bulletin is being revised to include additional diagnostic information and clarify model usage. Please discard Corporate Bulletin Number 02-07-30-013D (Section 07 -- Transmission/Transaxle). Condition Some owners may comment on any one or more of the following conditions: ^ The SES lamp is illuminated. ^ The transmission slips. ^ The transmission does not shift correctly, is very difficult to get the vehicle to start moving or the engine lacks the power to move the vehicle. ^ Poor engine performance. Cause The most likely cause of the various conditions may be chips or debris: ^ All years--Pressure Reg. Valve (Bore 1) or Torque Signal Valve (Bore 4) stuck ^ On 2001-2002 vehicles, a plugged orifice on the case side of the spacer plate. ^ ON 2003-2005 vehicles, restricted movement of the 2-3 shift valves in the valve body. ^ On 2003-2005 vehicles, restricted movement of the 3-4 shift valves in the valve body. Technician Diagnosis and Correction ^ The technician's road test reveals the vehicle launches in third or fourth gear (high RPM with slow vehicle acceleration). ^ On 2001-2002 vehicles, a DTC P0756 or P0757 may be stored. ^ On 2003-2005 vehicles, a DTC P0730, P0741, P0748 or P0757 may be stored. ^ Refer to the appropriate Service Information (SI) for additional Diagnostic Assistance. ^ With a Tech 2(R) connected to the vehicle, road test the vehicle and perform the following steps: If the above symptoms are present proceed with the following steps. 1. With the valve body removed and on a workbench, carefully push the valve against spring pressure to check if the valve will snap back to the original position. Or for the valves seated in home position, use a small flat-bladed screwdriver and carefully pry the valve off its seat, quickly remove the screwdriver allowing the valve to return to its seat. If the valve does not snap back unencumbered, then the valve will need to be removed from the valve body. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 4406 2. Once the valve is removed, inspect for any scratching or scoring. 3. If any scratching or scoring is found, then the fingernail test will need to be performed. Important: It has been found that in most cases that the scratches are not severe enough to catch your fingernail. 4. Using your fingernail, move over any scratches to see if your nail will catch on the scratch or score. - If your nail catches in the scratches, the valve will need to be replaced. - If your nail does not catch in the scratches, continue with the next step. 6. Important: Clean the valve body with the machined side down so debris may escape. 7. Clean the valve and bore using brake cleaner. 8. Blow off with shop air. 9. To verify free movement of the valve, dip the valve into clean ATF and install the valve back into the appropriate bore. The valve should move freely. If the valve moves freely, in most cases the valve body will function properly when reinstalled. 10. Reassemble and retest Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 4407 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 02-07-30-024B > Aug > 05 > A/T - Cracked Case Diagnosis Case: All Technical Service Bulletins A/T - Cracked Case Diagnosis Bulletin No.: 02-07-30-024B Date: August 18, 2005 INFORMATION Subject: Diagnosis of Cracked or Broken Transmission Case Models: 2006 and Prior Cars and Light Duty Trucks 2006 and Prior HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60/4L60-E/4L65-E or 4L80-E/4L85-E or Allison(R) Series 1000 Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 02-07-30-024A (Section 07 - Transmission/Transaxle). Diagnosing the cause of a cracked or broken transmission case requires additional diagnosis and repair or a repeat failure will occur. A cracked or broken transmission case is most often the result of abnormal external torsional forces acting on the transmission case. If none of the conditions listed below are apparent, an internal transmission component inspection may be required. Repairs of this type may be the result of external damage or abuse for which General Motors is not responsible. They are not the result of defects in materials or workmanship. If in doubt, contact your General Motors Service Representative. The following items should be considered: ^ It is important to inspect the vehicle for signs of an out of line condition, impact damage or foreign material to the following components: - The transmission - The engine mounts - The transmission rear mount and crossmember - Vehicle frame damage that alters the front to rear alignment of the driveshaft - The driveshafts (both front and rear) - The wheels (caked with mud, concrete, etc.) - The tires (roundness, lack of cupping, excessive balance weights) - The transfer case (if the vehicle is 4WD) ^ A worn or damaged driveshaft U-Joint has shown to be a frequent cause of transmission case cracking, especially on vehicles that see extended periods of highway driving. Always inspect the U-joint condition when diagnosing this condition. ^ For driveshaft damage or imbalance, Inspect the driveshafts (both front and rear) for dents, straightness/runout or signs of missing balance weights. Also, inspect for foreign material such as undercoat sprayed on the driveshaft. ^ The driveshaft working angles may be excessive or non-canceling, especially if the vehicle carrying height has been altered (lifted or lowered) or if the frame has been extended or modified. ^ Damaged or worn upper or lower rear control arms or bushings. ^ A rear axle that is not seated in the rear spring properly (leaf spring vehicles). ^ Broken rear springs and or worn leaf spring bushings. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 02-07-30-024B > Aug > 05 > A/T - Cracked Case Diagnosis > Page 4413 In some cases, the customer may not comment about a vibration but it is important to test drive the vehicle while using the electronic vibration analysis tool in an attempt to locate the cause of the torsional vibration. Refer to the Vibration Diagnosis and Correction sub-section of the appropriate Service Manual for more details on diagnosing and correcting vibrations. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Case: All Technical Service Bulletins A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Incorrect Transmission Shifts, Poor Engine Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck Off/On, DTCs P0757, P0741, P0742, P0730, P0756 # 02-07-30-013E - (May 20, 2005) Models: 2001-2005 GM Passenger Cars with 4T65-E Automatic Transmission 2001-2005 Buick Rendezvous 2005 Buick Terraza 2001-2004 Chevrolet Venture 2005 Chevrolet Uplander 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Montana 2005 Saturn Relay with 4T65-F Transmission (RPOs M15, MN3, MN7, M76) This bulletin is being revised to include additional diagnostic information and clarify model usage. Please discard Corporate Bulletin Number 02-07-30-013D (Section 07 -- Transmission/Transaxle). Condition Some owners may comment on any one or more of the following conditions: ^ The SES lamp is illuminated. ^ The transmission slips. ^ The transmission does not shift correctly, is very difficult to get the vehicle to start moving or the engine lacks the power to move the vehicle. ^ Poor engine performance. Cause The most likely cause of the various conditions may be chips or debris: ^ All years--Pressure Reg. Valve (Bore 1) or Torque Signal Valve (Bore 4) stuck ^ On 2001-2002 vehicles, a plugged orifice on the case side of the spacer plate. ^ ON 2003-2005 vehicles, restricted movement of the 2-3 shift valves in the valve body. ^ On 2003-2005 vehicles, restricted movement of the 3-4 shift valves in the valve body. Technician Diagnosis and Correction ^ The technician's road test reveals the vehicle launches in third or fourth gear (high RPM with slow vehicle acceleration). ^ On 2001-2002 vehicles, a DTC P0756 or P0757 may be stored. ^ On 2003-2005 vehicles, a DTC P0730, P0741, P0748 or P0757 may be stored. ^ Refer to the appropriate Service Information (SI) for additional Diagnostic Assistance. ^ With a Tech 2(R) connected to the vehicle, road test the vehicle and perform the following steps: If the above symptoms are present proceed with the following steps. 1. With the valve body removed and on a workbench, carefully push the valve against spring pressure to check if the valve will snap back to the original position. Or for the valves seated in home position, use a small flat-bladed screwdriver and carefully pry the valve off its seat, quickly remove the screwdriver allowing the valve to return to its seat. If the valve does not snap back unencumbered, then the valve will need to be removed from the valve body. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 4418 2. Once the valve is removed, inspect for any scratching or scoring. 3. If any scratching or scoring is found, then the fingernail test will need to be performed. Important: It has been found that in most cases that the scratches are not severe enough to catch your fingernail. 4. Using your fingernail, move over any scratches to see if your nail will catch on the scratch or score. - If your nail catches in the scratches, the valve will need to be replaced. - If your nail does not catch in the scratches, continue with the next step. 6. Important: Clean the valve body with the machined side down so debris may escape. 7. Clean the valve and bore using brake cleaner. 8. Blow off with shop air. 9. To verify free movement of the valve, dip the valve into clean ATF and install the valve back into the appropriate bore. The valve should move freely. If the valve moves freely, in most cases the valve body will function properly when reinstalled. 10. Reassemble and retest Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 4419 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Case: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4424 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4425 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4426 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4427 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure Technical Service Bulletin # 04-07-30-010 Date: 040303 A/T - 4T65-E Revised Side Cover Replacement Procedure Bulletin No.: 04-07-30-010 Date: March 03, 2004 SERVICE MANUAL UPDATE Subject: Revised Case Side Cover Replacement Procedure Models: 2004 Buick Regal 2004 Chevrolet Impala, Monte Carlo 2004 Pontiac Grand Prix This bulletin is being issued to revise the Case Side Cover Replacement procedure in the Automatic Transaxle - 4T65-E sub-section of the Service Manual. Please replace the current information in the Service Manual with the information shown in the service procedures. The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Impala, Monte Carlo Case Side Cover Replacement - Impala, Monte Carlo Removal Procedure Tools Required J 36850 Transjel Lubricant 1. Remove the engine dress cover. 2. Remove the air induction bellows between the throttle body and air cleaner assembly. 3. Disconnect the accelerator and cruise cables at throttle valve and remove the accelerator controls cable bracket. Refer to Accelerator Controls Cable Bracket Replacement in Engine Controls - 3.4L or Accelerator Controls Cable Bracket Replacement in Engine Controls - 3.8L. 4. Remove the transaxle shift cable from lever and bracket from the transaxle. 5. Disconnect the transaxle wiring harness connector and disconnect the harness retainer from side cover stud. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4432 6. Remove both engine supports from engine and radiator support. 7. Remove the top case side cover bolt (56, 58). 8. Install the engine support fixture and support engine/transaxle assembly. Refer to Engine Support Fixture in Engine Mechanical - 3.4L or Engine Support Fixture in Engine Mechanical 3.8L. 9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 10. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 11. Remove the inner fender splash shield. 12. Remove the wheel speed sensor harness from 4 retainers on the lower control arm. 13. Remove the transmission mount-to-frame nuts (2). 14. Remove both stabilizer links and reposition stabilizer to access steering gear-to-frame bolts. 15. Remove steering gear-to-frame bolts and support steering gear. 16. Remove the front splash shield. Refer to Splash Shield Replacement - Engine - Left and Splash Shield Replacement - Engine - Right in Body Front End. 17. Remove the positive battery cable center retainer at front frame rail. 18. Remove the left side ball joint and support the left frame rail with a jack stand. 19. Remove ONLY the left two frame-to-body bolts. DO NOT LOOSEN right side frame-to-body bolts. 20. Lower frame with a jackstand and remove jackstand. 21. Position the drain pan under the transaxle. 22. Remove the left drive axle from the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. 23. Secure the drive axle to the strut assembly. 24. Lower the vehicle. 25. Using the engine support fixture lower the engine assembly to access the transaxle case side cover. 26. Raise the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4433 27. Remove the transaxle mount bracket bolts and the bracket from the transaxle. 28. Remove the remaining case side cover bolts (56, 57, 58). 29. Remove the case side cover (53). 30. Remove the case side cover gasket (54). 31. Remove the case side cover 0-ring (59). 32. Clean the side cover gasket mating surfaces. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4434 1. Install the J 36850 to the case side cover 0-ring (59). 2. Install the 0-ring (59) to the case side cover. 3. Install the case side cover gasket (54). 4. Install the case side cover (53), by first installing any 2 of the upper case side cover bolts (56, 58). Note: Refer to Fastener Notice in Cautions and Notices. 5. Install the case side cover bolts (56, 57, 58). Tighten Tighten bolts to 25 N.m (18 lb ft). 6. Install the transaxle mount bracket 7. Install the transaxle mount bracket bolts. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4435 Tighten Tighten the bolts to 95 N.m (70 lb ft) 8. Install a jackstand under the left frame rail and raise frame while aligning transaxle mount bolts with frame and ball joint with steering knuckle. 9. Install and tighten left side frame-to-body bolts (2). 10. Install the drive axle to the transaxle. 11. Remove the drain pan from under the transaxle. 12. Install transaxle mount nuts (2). 13. Install the ball joint nut and cotter pin. 14. Install steering gear-to-frame bolts. 15. Install the positive battery cable center retainer on the front frame rail. 16. Reposition the stabilizer bar and install bolts-to-lower control arms. 17. Install the front splash shield. Refer to Splash Shield Replacement - engine - Left and Splash Shield Replacement - Engine - Right in Body Front End. 18. Install the wheel speed sensor harness to 4 retainers on the lower control arm. 19. Install the inner fender splash shield. 20. Install the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 21. Lower the vehicle. 22. Remove the engine support fixture. 23. Install the top case side cover bolt. Tighten Tighten bolts to 25 N.m (18 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4436 24. Install the shift cable to the shift lever and transaxle shift cable bracket bolts to shift cable bracket. Tighten Tighten bolts to 30 N.m (22 lb ft). 25. Connect the transaxle wiring harness connector, and harness retainer to side cover stud. 26. Install the engine mount struts. Refer to Engine Mount Strut Replacement - Left and Engine Strut Mount Replacement - Right in Engine Mechanical - 3.4L or Engine Strut Mount Replacement - Left and Engine Strut Mount Replacement - Right in Engine Mechanical - 3.8L. 27. Install the accelerator cable bracket with the accelerator and cruise control cables. Refer to Accelerator Controls Cable Bracket Replacement in Engine Controls - 3.4L or Accelerator Controls Cable Bracket Replacement in Engine Controls - 3.8L. 28. Install the air induction duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls 3.4L or Air Cleaner Intake Duct Replacement in Engine Controls - 3.8L. 29. Install the engine dress cover. Note: Refer to Do Not Overfill the Transmission Notice in Cautions and Notices. 30. Check and fill the transaxle as necessary. 31. Inspect for fluid leaks. Grand Prix Case Side Cover Replacement - Grand Prix Removal Procedure Tools Required J 36850 Transjel Lubricant 1. Remove the engine dress cover. 2. Disconnect the MAF sensor harness connector from the MAF and disconnect the air intake duct from throttle body. 3. Disconnect the EVAP emission hose from the EVAP valve. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4437 4. Remove the transaxle shift cable from the shift lever. 5. Remove the transaxle shift cable bracket bolts and the bracket from the transaxle. 6. Disconnect the transaxle wiring harness connector. 7. Remove both engine supports from the engine and radiator support. 8. Remove top side cover bolt (56, 58). 9. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.8L. 10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 11. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 12. Remove the inner fender splash shield. 13. Remove the wheel speed sensor harness from 4 retainers on lower control arm. 14. Remove the transmission mount-to-frame nuts (2). 15. Using side cutters, remove the plastic pencil-like support on the left side of the front splash shield, just below the left front frame bolt. 16. Remove the front cradle to radiator support brackets on each side. 17. Remove both stabilizer links from the stabilizer and reposition stabilizer to access steering gear-to-frame bolts. 18. Remove steering gear-to-frame bolts and support steering gear. 19. Remove the positive battery cable center retainer at front rail. 20. Remove the left side ball joint from the steering knuckle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4438 21. Support the left frame rail with a jack stand. 22. Remove only the left two frame-to-body bolts. DO NOT LOOSEN RIGHT SIDE FRAME-TO-BODY BOLTS. 23. Lower the frame with jack stand and remove jack stand. 24. Position the drain pan under transaxle side cover. 25. Remove the left drive axle from the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. 26. Secure the drive axle to the strut assembly. 27. Lower the vehicle. 28. Using the engine support fixture lower the engine assembly to access the transaxle case side cover. 29. Raise the vehicle. 30. Remove the transaxle mount bracket bolts and the bracket from the transaxle. 31. Remove the remaining case side cover bolts (56, 57, 58). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4439 32. Remove the case side cover (53). 33. Remove the case side cover gasket (54). 34. Remove the case side cover 0-ring (59). 35. Clean the side cover gasket mating surfaces. Installation Procedure 1. Install the J 36850 Transjel Lubricant to the case side cover 0-ring (59). 2. Install the 0-ring (59) to the case side cover. 3. Install the case side cover gasket (54). 4. Install the case side cover (53). Note: Refer to Fastener Notice in Cautions and Notices. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4440 5. Install the case side cover bolts (56, 57, 58) except top bolt. Tighten Tighten bolts to 25 N.m (18 lb ft). 6. Install the transaxle mount bracket. 7. Install the transaxle mount bracket bolts. Tighten Tighten the bolts to 95 N.m (70 lb ft) 8. Install a jack stand under the left frame rail and raise frame while aligning transaxle mount bolts with frame and ball joint with the steering knuckle. 9. Install and tighten the left side frame-to-body bolts (2). 10. Install front cradle to radiator support brackets and bolts to both sides. 11. Install drive axle to transaxle. 12. Install transaxle mount nuts (2). 13. Install the ball joint nut and cotter pin. 14. Install the steering gear-to-frame bolts. 15. Install the positive battery cable center retainer on front frame rail. 16. Reposition the stabilizer bar and install bolts to stabilizer. 17. Install the wheel speed sensor harness to four retainers on the lower control arm. 18. Install the inner fender splash shield. 19. Install the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4441 20. Lower the vehicle and remove the engine support fixture. 21. Install the top case side cover bolt. Tighten Tighten bolts to 25 N.m (18 lb ft). 22. Install the transaxle shift cable bracket and shift cable bracket bolts. Tighten Tighten the bolts to 30 N.m (22 lb ft). 23. Install the transaxle shift cable to the shift lever. 24. Connect the transaxle wiring harness connector. 25. Install the engine mount struts. Refer to Engine Mount Strut Replacement - Right and Engine Mount Strut Replacement - Left in Engine Mechanical - 3.8L. 26. Install the air intake duct and connect the MAF sensor wiring harness. 27. Install the EVAP hose to EVAP valve. 28. Install the engine dress cover. Note: Refer to Do Not Overfill the Transmission Notice in Cautions and Notices. 29. Check and fill the transaxle as necessary. 30. Inspect for fluid leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4442 Regal Case Side Cover Replacement - Regal Removal Procedure Important: Lock steering wheel in centered position with wheels straight ahead. 1. Remove the engine dress cover. 2. Remove the air cleaner intake duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.1 L or Air Cleaner Intake Duct Replacement in Engine Controls - 3.8L. 3. Remove the engine mount struts. Refer to Engine Mount Strut Replacement in Engine Mechanical - 3.1 L or Engine Mount Strut Replacement - Right and Engine Mount Strut Replacement - Left in Engine Mechanical - 3.8L. Important: For supercharged engines, remove the throttle cable bracket. 4. Disconnect the shift cable bracket. 5. Remove the transaxle top side cover bolt. 6. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.1 L or Engine Support Fixture in Engine Mechanical - 3.8L. 7. Disconnect the transmission wiring harness connector. 8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 9. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 10. Remove the left inner splash shield 3 push pins. 11. Loosen the wheel speed sensor harness from the 5 retainers at the cradle. 12. Remove the transmission support to cradle nuts only. Refer to Automatic Transmission Mount Replacement. 13. Raise the vehicle. 14. Remove the front splash shield 5 bolts. 15. Loosen the engine mount lower nuts. Refer to Engine Mount Bracket Replacement in Engine Mechanical - 3.1L or Engine Mount and Bracket Replacement in Engine Mechanical - 3.8L. 16. Remove the stabilizer bolts and reposition the stabilizer. 17. Remove the steering gear cradle bolts, then support gear before lowering cradle. 18. Support the left side of the frame with a jackstand. 19. Remove the left side frame bolts. DO NOT loosen the right front or the right rear frame bolts. Refer to Frame Replacement in Frame and Underbody. 20. Remove the left ball joint from the steering knuckle. 21. Position the drain pan under the transaxle. 22. Remove the left drive axle from the transaxle. Refer to Wheel Drive Shaft Replacement in Drive Axle. 23. Secure the drive axle to the steering knuckle/strut. 24. Adjust the jackstand to lower the left side of the frame until it hangs free. Remove jack stand. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4443 25. Lower vehicle to access engine support fixture. 26. Lower the engine/transmission assembly with the engine support fixture to gain access to remaining side cover bolts. 27. If replacing the side cover, remove 4 engine mount bracket bolts. 28. Remove the harness retainer. 29. Raise vehicle to access side cover bolts. 30. Remove the case side cover bolts (56-58). 31. Remove the case side cover pan (53). 32. Remove the case side cover gasket (54). 33. Clean the case. 34. Clean the side cover gasket mating surfaces. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4444 1. Install the case side cover gasket (54). 2. Install the case side cover pan (53). Note: Refer to Fastener Notice in Cautions and Notices. 3. Install the case side cover bolts (56-58) except for the top bolt. Tighten Tighten bolts (56-58) to 25 N.m (18 lb ft). 4. Install the left drive axle to the transaxle. Refer to Wheel Drive Shaft Replacement in Drive Axle. 5. Raise the vehicle. 6. Use a jackstand to raise the left side of the cradle and engine assembly into position. 7. Install the left ball joint into knuckle. 8. Install the left side frame bolts. Tighten Tighten the bolts to 165 N.m (122 lb ft). 9. Install the engine mount lower nuts. Refer to Engine Mount Bracket Replacement in Engine Mechanical - 3.1 L or Engine Mount and Bracket Replacement in Engine Mechanical - 3.8L. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4445 10. Install the transaxle mount nuts. Tighten Tighten the nuts to 47 N.m (35 lb ft). 11. Remove the jackstands from the frame. 12. Remove the drain pan from under the transaxle. 13. Install the ball joint nut, and cotter pin. 14. Install the steering gear cradle bolts. Tighten Tighten the bolts to 80 N.m (59 lb ft). 15. Reposition the stabilizer and install the stabilizer bolts. Tighten Tighten the bolts to 23 N.m (17 lb ft). 16. Install the front splash shield 5 bolts. 17. Lower the vehicle. 18. Install two engine mount bolts. Tighten Tighten the bolts to 47 N.m (35 lb ft). 19. Install the wheel speed sensor harness to the 5 retainers at the cradle. 20. Install the left inner splash shield 3 push pins. 21. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 22. Lower the vehicle. 23. Remove the engine support fixture. 24. Connect the shift cable bracket. 25. Install the transaxle top side cover bolt. 26. Connect the transaxle wiring harness connector. Important: Install the throttle cable bracket, if previously removed (Supercharged). 27. Install the engine mount struts. Refer to Engine Mount Strut Replacement in Engine Mechanical - 3.1 L or Engine Mount Strut Replacement - Right and Engine Mount Strut Replacement - Left in Engine Mechanical - 3.8L. 28. Install the throttle body air inlet duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.1 L or Air Cleaner Intake Duct Replacement in Engine Controls - 3.8L. 29. Install the engine dress cover. Note: Refer to Transmission Overfill Notice in Cautions and Notices. 30. Check and fill the transaxle as necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4446 31. Inspect for fluid leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 02-07-30-024B > Aug > 05 > A/T - Cracked Case Diagnosis Case: All Technical Service Bulletins A/T - Cracked Case Diagnosis Bulletin No.: 02-07-30-024B Date: August 18, 2005 INFORMATION Subject: Diagnosis of Cracked or Broken Transmission Case Models: 2006 and Prior Cars and Light Duty Trucks 2006 and Prior HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X with 4L60/4L60-E/4L65-E or 4L80-E/4L85-E or Allison(R) Series 1000 Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 02-07-30-024A (Section 07 - Transmission/Transaxle). Diagnosing the cause of a cracked or broken transmission case requires additional diagnosis and repair or a repeat failure will occur. A cracked or broken transmission case is most often the result of abnormal external torsional forces acting on the transmission case. If none of the conditions listed below are apparent, an internal transmission component inspection may be required. Repairs of this type may be the result of external damage or abuse for which General Motors is not responsible. They are not the result of defects in materials or workmanship. If in doubt, contact your General Motors Service Representative. The following items should be considered: ^ It is important to inspect the vehicle for signs of an out of line condition, impact damage or foreign material to the following components: - The transmission - The engine mounts - The transmission rear mount and crossmember - Vehicle frame damage that alters the front to rear alignment of the driveshaft - The driveshafts (both front and rear) - The wheels (caked with mud, concrete, etc.) - The tires (roundness, lack of cupping, excessive balance weights) - The transfer case (if the vehicle is 4WD) ^ A worn or damaged driveshaft U-Joint has shown to be a frequent cause of transmission case cracking, especially on vehicles that see extended periods of highway driving. Always inspect the U-joint condition when diagnosing this condition. ^ For driveshaft damage or imbalance, Inspect the driveshafts (both front and rear) for dents, straightness/runout or signs of missing balance weights. Also, inspect for foreign material such as undercoat sprayed on the driveshaft. ^ The driveshaft working angles may be excessive or non-canceling, especially if the vehicle carrying height has been altered (lifted or lowered) or if the frame has been extended or modified. ^ Damaged or worn upper or lower rear control arms or bushings. ^ A rear axle that is not seated in the rear spring properly (leaf spring vehicles). ^ Broken rear springs and or worn leaf spring bushings. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 02-07-30-024B > Aug > 05 > A/T - Cracked Case Diagnosis > Page 4452 In some cases, the customer may not comment about a vibration but it is important to test drive the vehicle while using the electronic vibration analysis tool in an attempt to locate the cause of the torsional vibration. Refer to the Vibration Diagnosis and Correction sub-section of the appropriate Service Manual for more details on diagnosing and correcting vibrations. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Case: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4457 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4458 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4459 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4460 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure Technical Service Bulletin # 04-07-30-010 Date: 040303 A/T - 4T65-E Revised Side Cover Replacement Procedure Bulletin No.: 04-07-30-010 Date: March 03, 2004 SERVICE MANUAL UPDATE Subject: Revised Case Side Cover Replacement Procedure Models: 2004 Buick Regal 2004 Chevrolet Impala, Monte Carlo 2004 Pontiac Grand Prix This bulletin is being issued to revise the Case Side Cover Replacement procedure in the Automatic Transaxle - 4T65-E sub-section of the Service Manual. Please replace the current information in the Service Manual with the information shown in the service procedures. The information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Impala, Monte Carlo Case Side Cover Replacement - Impala, Monte Carlo Removal Procedure Tools Required J 36850 Transjel Lubricant 1. Remove the engine dress cover. 2. Remove the air induction bellows between the throttle body and air cleaner assembly. 3. Disconnect the accelerator and cruise cables at throttle valve and remove the accelerator controls cable bracket. Refer to Accelerator Controls Cable Bracket Replacement in Engine Controls - 3.4L or Accelerator Controls Cable Bracket Replacement in Engine Controls - 3.8L. 4. Remove the transaxle shift cable from lever and bracket from the transaxle. 5. Disconnect the transaxle wiring harness connector and disconnect the harness retainer from side cover stud. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4465 6. Remove both engine supports from engine and radiator support. 7. Remove the top case side cover bolt (56, 58). 8. Install the engine support fixture and support engine/transaxle assembly. Refer to Engine Support Fixture in Engine Mechanical - 3.4L or Engine Support Fixture in Engine Mechanical 3.8L. 9. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 10. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 11. Remove the inner fender splash shield. 12. Remove the wheel speed sensor harness from 4 retainers on the lower control arm. 13. Remove the transmission mount-to-frame nuts (2). 14. Remove both stabilizer links and reposition stabilizer to access steering gear-to-frame bolts. 15. Remove steering gear-to-frame bolts and support steering gear. 16. Remove the front splash shield. Refer to Splash Shield Replacement - Engine - Left and Splash Shield Replacement - Engine - Right in Body Front End. 17. Remove the positive battery cable center retainer at front frame rail. 18. Remove the left side ball joint and support the left frame rail with a jack stand. 19. Remove ONLY the left two frame-to-body bolts. DO NOT LOOSEN right side frame-to-body bolts. 20. Lower frame with a jackstand and remove jackstand. 21. Position the drain pan under the transaxle. 22. Remove the left drive axle from the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. 23. Secure the drive axle to the strut assembly. 24. Lower the vehicle. 25. Using the engine support fixture lower the engine assembly to access the transaxle case side cover. 26. Raise the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4466 27. Remove the transaxle mount bracket bolts and the bracket from the transaxle. 28. Remove the remaining case side cover bolts (56, 57, 58). 29. Remove the case side cover (53). 30. Remove the case side cover gasket (54). 31. Remove the case side cover 0-ring (59). 32. Clean the side cover gasket mating surfaces. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4467 1. Install the J 36850 to the case side cover 0-ring (59). 2. Install the 0-ring (59) to the case side cover. 3. Install the case side cover gasket (54). 4. Install the case side cover (53), by first installing any 2 of the upper case side cover bolts (56, 58). Note: Refer to Fastener Notice in Cautions and Notices. 5. Install the case side cover bolts (56, 57, 58). Tighten Tighten bolts to 25 N.m (18 lb ft). 6. Install the transaxle mount bracket 7. Install the transaxle mount bracket bolts. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4468 Tighten Tighten the bolts to 95 N.m (70 lb ft) 8. Install a jackstand under the left frame rail and raise frame while aligning transaxle mount bolts with frame and ball joint with steering knuckle. 9. Install and tighten left side frame-to-body bolts (2). 10. Install the drive axle to the transaxle. 11. Remove the drain pan from under the transaxle. 12. Install transaxle mount nuts (2). 13. Install the ball joint nut and cotter pin. 14. Install steering gear-to-frame bolts. 15. Install the positive battery cable center retainer on the front frame rail. 16. Reposition the stabilizer bar and install bolts-to-lower control arms. 17. Install the front splash shield. Refer to Splash Shield Replacement - engine - Left and Splash Shield Replacement - Engine - Right in Body Front End. 18. Install the wheel speed sensor harness to 4 retainers on the lower control arm. 19. Install the inner fender splash shield. 20. Install the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 21. Lower the vehicle. 22. Remove the engine support fixture. 23. Install the top case side cover bolt. Tighten Tighten bolts to 25 N.m (18 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4469 24. Install the shift cable to the shift lever and transaxle shift cable bracket bolts to shift cable bracket. Tighten Tighten bolts to 30 N.m (22 lb ft). 25. Connect the transaxle wiring harness connector, and harness retainer to side cover stud. 26. Install the engine mount struts. Refer to Engine Mount Strut Replacement - Left and Engine Strut Mount Replacement - Right in Engine Mechanical - 3.4L or Engine Strut Mount Replacement - Left and Engine Strut Mount Replacement - Right in Engine Mechanical - 3.8L. 27. Install the accelerator cable bracket with the accelerator and cruise control cables. Refer to Accelerator Controls Cable Bracket Replacement in Engine Controls - 3.4L or Accelerator Controls Cable Bracket Replacement in Engine Controls - 3.8L. 28. Install the air induction duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls 3.4L or Air Cleaner Intake Duct Replacement in Engine Controls - 3.8L. 29. Install the engine dress cover. Note: Refer to Do Not Overfill the Transmission Notice in Cautions and Notices. 30. Check and fill the transaxle as necessary. 31. Inspect for fluid leaks. Grand Prix Case Side Cover Replacement - Grand Prix Removal Procedure Tools Required J 36850 Transjel Lubricant 1. Remove the engine dress cover. 2. Disconnect the MAF sensor harness connector from the MAF and disconnect the air intake duct from throttle body. 3. Disconnect the EVAP emission hose from the EVAP valve. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4470 4. Remove the transaxle shift cable from the shift lever. 5. Remove the transaxle shift cable bracket bolts and the bracket from the transaxle. 6. Disconnect the transaxle wiring harness connector. 7. Remove both engine supports from the engine and radiator support. 8. Remove top side cover bolt (56, 58). 9. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.8L. 10. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 11. Remove the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 12. Remove the inner fender splash shield. 13. Remove the wheel speed sensor harness from 4 retainers on lower control arm. 14. Remove the transmission mount-to-frame nuts (2). 15. Using side cutters, remove the plastic pencil-like support on the left side of the front splash shield, just below the left front frame bolt. 16. Remove the front cradle to radiator support brackets on each side. 17. Remove both stabilizer links from the stabilizer and reposition stabilizer to access steering gear-to-frame bolts. 18. Remove steering gear-to-frame bolts and support steering gear. 19. Remove the positive battery cable center retainer at front rail. 20. Remove the left side ball joint from the steering knuckle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4471 21. Support the left frame rail with a jack stand. 22. Remove only the left two frame-to-body bolts. DO NOT LOOSEN RIGHT SIDE FRAME-TO-BODY BOLTS. 23. Lower the frame with jack stand and remove jack stand. 24. Position the drain pan under transaxle side cover. 25. Remove the left drive axle from the transaxle. Refer to Wheel Drive Shaft Replacement in Wheel Drive Shafts. 26. Secure the drive axle to the strut assembly. 27. Lower the vehicle. 28. Using the engine support fixture lower the engine assembly to access the transaxle case side cover. 29. Raise the vehicle. 30. Remove the transaxle mount bracket bolts and the bracket from the transaxle. 31. Remove the remaining case side cover bolts (56, 57, 58). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4472 32. Remove the case side cover (53). 33. Remove the case side cover gasket (54). 34. Remove the case side cover 0-ring (59). 35. Clean the side cover gasket mating surfaces. Installation Procedure 1. Install the J 36850 Transjel Lubricant to the case side cover 0-ring (59). 2. Install the 0-ring (59) to the case side cover. 3. Install the case side cover gasket (54). 4. Install the case side cover (53). Note: Refer to Fastener Notice in Cautions and Notices. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4473 5. Install the case side cover bolts (56, 57, 58) except top bolt. Tighten Tighten bolts to 25 N.m (18 lb ft). 6. Install the transaxle mount bracket. 7. Install the transaxle mount bracket bolts. Tighten Tighten the bolts to 95 N.m (70 lb ft) 8. Install a jack stand under the left frame rail and raise frame while aligning transaxle mount bolts with frame and ball joint with the steering knuckle. 9. Install and tighten the left side frame-to-body bolts (2). 10. Install front cradle to radiator support brackets and bolts to both sides. 11. Install drive axle to transaxle. 12. Install transaxle mount nuts (2). 13. Install the ball joint nut and cotter pin. 14. Install the steering gear-to-frame bolts. 15. Install the positive battery cable center retainer on front frame rail. 16. Reposition the stabilizer bar and install bolts to stabilizer. 17. Install the wheel speed sensor harness to four retainers on the lower control arm. 18. Install the inner fender splash shield. 19. Install the left front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4474 20. Lower the vehicle and remove the engine support fixture. 21. Install the top case side cover bolt. Tighten Tighten bolts to 25 N.m (18 lb ft). 22. Install the transaxle shift cable bracket and shift cable bracket bolts. Tighten Tighten the bolts to 30 N.m (22 lb ft). 23. Install the transaxle shift cable to the shift lever. 24. Connect the transaxle wiring harness connector. 25. Install the engine mount struts. Refer to Engine Mount Strut Replacement - Right and Engine Mount Strut Replacement - Left in Engine Mechanical - 3.8L. 26. Install the air intake duct and connect the MAF sensor wiring harness. 27. Install the EVAP hose to EVAP valve. 28. Install the engine dress cover. Note: Refer to Do Not Overfill the Transmission Notice in Cautions and Notices. 29. Check and fill the transaxle as necessary. 30. Inspect for fluid leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4475 Regal Case Side Cover Replacement - Regal Removal Procedure Important: Lock steering wheel in centered position with wheels straight ahead. 1. Remove the engine dress cover. 2. Remove the air cleaner intake duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.1 L or Air Cleaner Intake Duct Replacement in Engine Controls - 3.8L. 3. Remove the engine mount struts. Refer to Engine Mount Strut Replacement in Engine Mechanical - 3.1 L or Engine Mount Strut Replacement - Right and Engine Mount Strut Replacement - Left in Engine Mechanical - 3.8L. Important: For supercharged engines, remove the throttle cable bracket. 4. Disconnect the shift cable bracket. 5. Remove the transaxle top side cover bolt. 6. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.1 L or Engine Support Fixture in Engine Mechanical - 3.8L. 7. Disconnect the transmission wiring harness connector. 8. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. 9. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 10. Remove the left inner splash shield 3 push pins. 11. Loosen the wheel speed sensor harness from the 5 retainers at the cradle. 12. Remove the transmission support to cradle nuts only. Refer to Automatic Transmission Mount Replacement. 13. Raise the vehicle. 14. Remove the front splash shield 5 bolts. 15. Loosen the engine mount lower nuts. Refer to Engine Mount Bracket Replacement in Engine Mechanical - 3.1L or Engine Mount and Bracket Replacement in Engine Mechanical - 3.8L. 16. Remove the stabilizer bolts and reposition the stabilizer. 17. Remove the steering gear cradle bolts, then support gear before lowering cradle. 18. Support the left side of the frame with a jackstand. 19. Remove the left side frame bolts. DO NOT loosen the right front or the right rear frame bolts. Refer to Frame Replacement in Frame and Underbody. 20. Remove the left ball joint from the steering knuckle. 21. Position the drain pan under the transaxle. 22. Remove the left drive axle from the transaxle. Refer to Wheel Drive Shaft Replacement in Drive Axle. 23. Secure the drive axle to the steering knuckle/strut. 24. Adjust the jackstand to lower the left side of the frame until it hangs free. Remove jack stand. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4476 25. Lower vehicle to access engine support fixture. 26. Lower the engine/transmission assembly with the engine support fixture to gain access to remaining side cover bolts. 27. If replacing the side cover, remove 4 engine mount bracket bolts. 28. Remove the harness retainer. 29. Raise vehicle to access side cover bolts. 30. Remove the case side cover bolts (56-58). 31. Remove the case side cover pan (53). 32. Remove the case side cover gasket (54). 33. Clean the case. 34. Clean the side cover gasket mating surfaces. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4477 1. Install the case side cover gasket (54). 2. Install the case side cover pan (53). Note: Refer to Fastener Notice in Cautions and Notices. 3. Install the case side cover bolts (56-58) except for the top bolt. Tighten Tighten bolts (56-58) to 25 N.m (18 lb ft). 4. Install the left drive axle to the transaxle. Refer to Wheel Drive Shaft Replacement in Drive Axle. 5. Raise the vehicle. 6. Use a jackstand to raise the left side of the cradle and engine assembly into position. 7. Install the left ball joint into knuckle. 8. Install the left side frame bolts. Tighten Tighten the bolts to 165 N.m (122 lb ft). 9. Install the engine mount lower nuts. Refer to Engine Mount Bracket Replacement in Engine Mechanical - 3.1 L or Engine Mount and Bracket Replacement in Engine Mechanical - 3.8L. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4478 10. Install the transaxle mount nuts. Tighten Tighten the nuts to 47 N.m (35 lb ft). 11. Remove the jackstands from the frame. 12. Remove the drain pan from under the transaxle. 13. Install the ball joint nut, and cotter pin. 14. Install the steering gear cradle bolts. Tighten Tighten the bolts to 80 N.m (59 lb ft). 15. Reposition the stabilizer and install the stabilizer bolts. Tighten Tighten the bolts to 23 N.m (17 lb ft). 16. Install the front splash shield 5 bolts. 17. Lower the vehicle. 18. Install two engine mount bolts. Tighten Tighten the bolts to 47 N.m (35 lb ft). 19. Install the wheel speed sensor harness to the 5 retainers at the cradle. 20. Install the left inner splash shield 3 push pins. 21. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels. 22. Lower the vehicle. 23. Remove the engine support fixture. 24. Connect the shift cable bracket. 25. Install the transaxle top side cover bolt. 26. Connect the transaxle wiring harness connector. Important: Install the throttle cable bracket, if previously removed (Supercharged). 27. Install the engine mount struts. Refer to Engine Mount Strut Replacement in Engine Mechanical - 3.1 L or Engine Mount Strut Replacement - Right and Engine Mount Strut Replacement - Left in Engine Mechanical - 3.8L. 28. Install the throttle body air inlet duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.1 L or Air Cleaner Intake Duct Replacement in Engine Controls - 3.8L. 29. Install the engine dress cover. Note: Refer to Transmission Overfill Notice in Cautions and Notices. 30. Check and fill the transaxle as necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Case: > 04-07-30-010 > Mar > 04 > A/T - 4T65-E Revised Side Cover Replacement Procedure > Page 4479 31. Inspect for fluid leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 4480 Case: Service and Repair Case Side Cover Replacement Removal Procedure Tools Required ^ J 36850 Transjel Lubricant 1. Disconnect the negative battery cable. 2. Remove the air cleaner intake duct. 3. Remove the accelerator cable bracket with the accelerator and cruise control cables. 4. Remove the transaxle shift cable from the shift lever. 5. Remove the transaxle shift cable bracket bolts and the bracket from the transaxle. 6. Disconnect the transaxle wiring harness connector. 7. Remove the top four case side cover bolts (56, 58). 8. Install the engine support fixture. 9. Raise and support the vehicle. 10. Remove the frame assembly. 11. Remove the left drive axle from the transaxle. 12. Secure the drive axle to the strut assembly. 13. Lower the vehicle. 14. Using the engine support fixture lower the engine assembly to access the transaxle case side cover. 15. Raise the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 4481 16. Remove the transaxle mount bracket bolts and the bracket from the transaxle. 17. Position the drain pan under the transaxle. 18. Remove the remaining case side cover bolts (56, 57, 58). 19. Remove the case side cover (53). 20. Remove the case side cover gasket (54). 21. Remove the case side cover O-ring (59). 22. Clean the side cover gasket mating surfaces. Installation Procedure 1. Install the J 36850 Transjel Lubricant to the case side cover O-ring (59). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 4482 2. Install the O-ring (59) to the case side cover. 3. Install the case side cover gasket (54). 4. Install the case side cover (53). Notice: Refer to Fastener Notice in Service precautions. 5. Install the case side cover bolts (56, 57, 58). Tighten bolts to 25 Nm (18 ft. lbs.). 6. Remove the drain pan from under the transaxle. 7. Install the transaxle mount bracket 8. Install the transaxle mount bracket bolts. Tighten the bolts to 95 Nm (70 ft. lbs.) 9. Lower the vehicle. 10. Using the engine support fixture raise the engine assembly to the original position 11. Raise the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Case, A/T > Component Information > Technical Service Bulletins > Page 4483 12. Install the left drive axle to the transaxle. 13. Install the frame assembly. 14. Lower the vehicle. 15. Remove the engine support fixture. 16. Install the top four case side cover bolts. Tighten bolts to 25 Nm (18 ft. lbs.). 17. Connect the transaxle wiring harness connector. 18. Install the engine mount struts. 19. Install the transaxle shift cable bracket. 20. Install the transaxle shift cable bracket bolts. Tighten the bolts to 30 Nm (22 ft. lbs.). 21. Install the transaxle shift cable to the shift lever. 22. Install the accelerator cable bracket with the accelerator and cruise control cables. 23. Install the air cleaner intake duct. 24. Connect the negative battery cable. Notice: Refer to Do Not Overfill the Transmission Notice. 25. Check and fill the transaxle as necessary. 26. Inspect for fluid leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 4492 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Channel Plate: Customer Interest A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4497 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4498 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Channel Plate: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 4508 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Channel Plate: All Technical Service Bulletins A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4513 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4514 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 03-07-30-029 > Jul > 03 > A/T - 4T65E Internal Updates Channel Plate: All Technical Service Bulletins A/T - 4T65E Internal Updates Bulletin No.: 03-07-30-029 Date: July 15, 2003 INFORMATION Subject: Changes for 2004 Model Year for 4T65E Transaxle - Internal Changes to Valve Body, Spacer Plate and Channel Plate and Touch Activated Power (TAP) Models: 2004 Buick Century, LeSabre, Park Avenue, Regal, Rendezvous 2004 Chevrolet Impala, Monte Carlo, Venture 2004 Oldsmobile Silhouette 2004 Pontiac Aztek, Bonneville, Grand Prix, Montana with 4T65E Transaxle (RPOs MN3, MN7, M15, M76) Important: This bulletin mainly deals with the features of the new Touch Activated Power feature of the 4T65E transaxle, which is only available on the supercharged Grand Prix. However, it is important for technicians to familiarize themselves with the differences between the TAP-equipped transaxle and the non-TAP equipped transaxle. There are several components of the transaxle that are unique to TAP. These components are NOT INTERCHANGEABLE with the same components on a non-TAP equipped 4T65E transaxle. If the correct parts are not used, serious driveability concerns could result. The purpose of this bulletin is to introduce new features of the 4T65E transaxle for the 2004 model year. Valve Body, Spacer Plate and Channel Plate. Valve Body, Spacer Plate and Channel Plate The internal changes to the 4T65E transmission are in the valve body, spacer plate and the channel plate. These parts are unique to the Touch Activated Power (TAP)-equipped 4T65E transmission. (TAP is only available on supercharged Grand Prix models.) A non-TAP transmission has a different valve body, spacer plate and channel plate. DO NOT MIX THE PARTS. If incorrect parts are installed, there will be shifting concerns. Any test drives should include TAP-Shift(TM) operation. Channel Plate and Valve Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 03-07-30-029 > Jul > 03 > A/T - 4T65E Internal Updates > Page 4519 The TAP channel plate and valve is shown on the left-hand side of the illustration. The non-TAP channel plate and valve is shown on the right. Spacer Plate The new TAP spacer plate has three notches in the lower right corner. The new non-TAP spacer plate has no notches in the lower right corner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 03-07-30-029 > Jul > 03 > A/T - 4T65E Internal Updates > Page 4520 The new TAP-equipped vehicle also has different fourth clutch plates, with fiber on one side and steel on the other. A non-TAP vehicle will have normal fiber and steel plates for the fourth clutch. The 2/1 manual band is made from a different material for TAP-Shift(TM) applications. This material will handle more stress than the normal 2/1 band in the other models. The transaxle filter has also changed to improve oil pickup. The new filter will back service any past model 4T65E and its use is required on all Century, Regal, Impala, Monte Carlo and Grand Prix vehicles for 2004. Performance Shifting with TAP-Shift(TM) (Available ONLY on Supercharged Grand Prix Models) If the vehicle is equipped with the 3800 V6 supercharged engine, it may have a console gearshift with a MANUAL (M) position. The other gearshift positions available are PARK (P), REVERSE (R), NEUTRAL (N) and AUTOMATIC OVERDRIVE (D). These positions operate as they have in the past. While in the MANUAL (M) position, the auto trans manual shift position switches, or paddles (located on the steering wheel), can be used to upshift or downshift the transaxle, under certain circumstances. Steering Wheel Shift Position Switch and Head Up Display Symbol While in the MANUAL (M) mode, push either paddle once to upshift to the next gear. Pull either paddle once to downshift to the next gear. To use the system, select MANUAL (M) while stopped, with the engine running. The vehicle will begin moving in first gear upon acceleration. For better control in icy or slippery conditions, the vehicle may start out in second gear, rather than in first. The upshift indicator light on the instrument panel, or the upshift symbol on the Head-Up Display (HUD) (if equipped), is given as a prompt to use the TAP-Shift(TM) paddle. These prompts to upshift as needed will be given throughout acceleration. If upshifting does not occur when prompted, the vehicle speed will be limited Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Channel Plate: > 03-07-30-029 > Jul > 03 > A/T - 4T65E Internal Updates > Page 4521 to protect the engine. Press the accelerator quickly while driving in the highest gear to make the transaxle automatically downshift. The transaxle will also automatically downshift as the vehicle decelerates and comes to a stop. When a paddle is pushed or pulled, a chime will sound when the vehicle cannot respond to a transaxle gear change. The system will not allow either an upshift or a downshift if the vehicle speed is too fast or slow, nor will it allow a start from third or higher gear. The MANUAL (M) gear can also be selected while the vehicle is already moving. The current transaxle position will continue to be displayed on the Driver Information Center (DIC) and HUD (if equipped). The transaxle upshifts and downshifts can be done using the TAP-Shift(TM) paddles as described previously. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Channel Plate: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 03-07-30-029 > Jul > 03 > A/T - 4T65E Internal Updates Channel Plate: All Technical Service Bulletins A/T - 4T65E Internal Updates Bulletin No.: 03-07-30-029 Date: July 15, 2003 INFORMATION Subject: Changes for 2004 Model Year for 4T65E Transaxle - Internal Changes to Valve Body, Spacer Plate and Channel Plate and Touch Activated Power (TAP) Models: 2004 Buick Century, LeSabre, Park Avenue, Regal, Rendezvous 2004 Chevrolet Impala, Monte Carlo, Venture 2004 Oldsmobile Silhouette 2004 Pontiac Aztek, Bonneville, Grand Prix, Montana with 4T65E Transaxle (RPOs MN3, MN7, M15, M76) Important: This bulletin mainly deals with the features of the new Touch Activated Power feature of the 4T65E transaxle, which is only available on the supercharged Grand Prix. However, it is important for technicians to familiarize themselves with the differences between the TAP-equipped transaxle and the non-TAP equipped transaxle. There are several components of the transaxle that are unique to TAP. These components are NOT INTERCHANGEABLE with the same components on a non-TAP equipped 4T65E transaxle. If the correct parts are not used, serious driveability concerns could result. The purpose of this bulletin is to introduce new features of the 4T65E transaxle for the 2004 model year. Valve Body, Spacer Plate and Channel Plate. Valve Body, Spacer Plate and Channel Plate The internal changes to the 4T65E transmission are in the valve body, spacer plate and the channel plate. These parts are unique to the Touch Activated Power (TAP)-equipped 4T65E transmission. (TAP is only available on supercharged Grand Prix models.) A non-TAP transmission has a different valve body, spacer plate and channel plate. DO NOT MIX THE PARTS. If incorrect parts are installed, there will be shifting concerns. Any test drives should include TAP-Shift(TM) operation. Channel Plate and Valve Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 03-07-30-029 > Jul > 03 > A/T - 4T65E Internal Updates > Page 4531 The TAP channel plate and valve is shown on the left-hand side of the illustration. The non-TAP channel plate and valve is shown on the right. Spacer Plate The new TAP spacer plate has three notches in the lower right corner. The new non-TAP spacer plate has no notches in the lower right corner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 03-07-30-029 > Jul > 03 > A/T - 4T65E Internal Updates > Page 4532 The new TAP-equipped vehicle also has different fourth clutch plates, with fiber on one side and steel on the other. A non-TAP vehicle will have normal fiber and steel plates for the fourth clutch. The 2/1 manual band is made from a different material for TAP-Shift(TM) applications. This material will handle more stress than the normal 2/1 band in the other models. The transaxle filter has also changed to improve oil pickup. The new filter will back service any past model 4T65E and its use is required on all Century, Regal, Impala, Monte Carlo and Grand Prix vehicles for 2004. Performance Shifting with TAP-Shift(TM) (Available ONLY on Supercharged Grand Prix Models) If the vehicle is equipped with the 3800 V6 supercharged engine, it may have a console gearshift with a MANUAL (M) position. The other gearshift positions available are PARK (P), REVERSE (R), NEUTRAL (N) and AUTOMATIC OVERDRIVE (D). These positions operate as they have in the past. While in the MANUAL (M) position, the auto trans manual shift position switches, or paddles (located on the steering wheel), can be used to upshift or downshift the transaxle, under certain circumstances. Steering Wheel Shift Position Switch and Head Up Display Symbol While in the MANUAL (M) mode, push either paddle once to upshift to the next gear. Pull either paddle once to downshift to the next gear. To use the system, select MANUAL (M) while stopped, with the engine running. The vehicle will begin moving in first gear upon acceleration. For better control in icy or slippery conditions, the vehicle may start out in second gear, rather than in first. The upshift indicator light on the instrument panel, or the upshift symbol on the Head-Up Display (HUD) (if equipped), is given as a prompt to use the TAP-Shift(TM) paddle. These prompts to upshift as needed will be given throughout acceleration. If upshifting does not occur when prompted, the vehicle speed will be limited Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Channel Plate, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Channel Plate: > 03-07-30-029 > Jul > 03 > A/T - 4T65E Internal Updates > Page 4533 to protect the engine. Press the accelerator quickly while driving in the highest gear to make the transaxle automatically downshift. The transaxle will also automatically downshift as the vehicle decelerates and comes to a stop. When a paddle is pushed or pulled, a chime will sound when the vehicle cannot respond to a transaxle gear change. The system will not allow either an upshift or a downshift if the vehicle speed is too fast or slow, nor will it allow a start from third or higher gear. The MANUAL (M) gear can also be selected while the vehicle is already moving. The current transaxle position will continue to be displayed on the Driver Information Center (DIC) and HUD (if equipped). The transaxle upshifts and downshifts can be done using the TAP-Shift(TM) paddles as described previously. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 06-07-30-023C > Oct > 09 > A/T 4T65E 1-2 Shift Shudder On Light Acceleration Clutch: Customer Interest A/T - 4T65E 1-2 Shift Shudder On Light Acceleration TECHNICAL Bulletin No.: 06-07-30-023C Date: October 15, 2009 Subject: 4T65E Transmission 1-2 Shift Shudder at Light to Moderate Acceleration (Replace Complete Second Clutch Assembly) Models: 2001-2004 Buick Regal 2001-2005 Buick Century, LeSabre 2002-2007 Buick Rendezvous 2005-2007 Buick Terraza, LaCrosse, Allure (Canada Only) 2006-2007 Buick Lucerne 2001-2005 Chevrolet Venture 2001-2007 Chevrolet Impala, Monte Carlo 2005-2007 Chevrolet Uplander 2006-2007 Chevrolet Malibu SS, Malibu Maxx SS 2001-2002 Oldsmobile Intrigue 2001-2003 Oldsmobile Aurora 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Bonneville, Montana 2001-2007 Pontiac Grand Prix 2005-2007 Pontiac Montana SV6 2006-2007 Pontiac G6 GTP 2005-2007 Saturn Relay with 4T65E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to update parts information. Please discard Corporate Bulletin Number 06-07-30-023B (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a 1-2 shift shudder at light to moderate acceleration. Typically, the throttle plate angle parameter is 12-20% at time of condition with vehicle speed of approximately 24-40 km/h (15-25 mph). The customer may describe the condition as slip or delayed shift into second. Correction Replace the complete second clutch assembly with service kit, P/N 24240561. Refer to the GM Unit Repair Service Manual for the year and model of the vehicle being serviced for the 2nd Clutch service procedure. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 06-07-30-023C > Oct > 09 > A/T 4T65E 1-2 Shift Shudder On Light Acceleration > Page 4542 This service kit contains: Second Clutch Housing Fluid Seal Rings (613), a Second Clutch Assembly (617), a Case Cover (Channel Plate) Upper Gasket (430), and a Case Cover (Channel Plate) Lower Gasket (429). In addition to the content of this service kit, other gaskets not included in this service kit will also be needed to complete the repair - a Case Cover Lower Gasket (429), and a Case Cover Upper Gasket (430). These gaskets can be obtained by ordering gasket kit 24206391. Be sure to use ONLY the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings provided in this service kit. DISCARD the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings removed from the transmission being serviced. Disassemble ONLY the Oil Pump Assembly from the Case Cover (Complete). DO NOT disassemble the Control Valve Body from the Case Cover. Remove ONLY the Case Cover-to-Case bolts to remove the Case Cover and Valve Body from Transmission Case AS AN ASSEMBLY. To access all Case Cover-to-Case bolts, it is necessary to remove the Pressure Control Solenoid Valve Assembly (322), and 1-2 & 3-4 Shift Solenoid Valve Assemblies (315A, 315B). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 06-07-30-023C > Oct > 09 > A/T 4T65E 1-2 Shift Shudder On Light Acceleration > Page 4543 Important This service kit does not contain the gaskets and/or seals necessary to service the Case Cover and Control Valve Body, if they are disassembled from each other. Please review the graphic above for Pump Body-to-Case (230), Pump Cover-to-Case (231), Control Valve Body-to-Case (377), Manual Shift Detent Assembly-to-Case (805), and Case Cover-to-Case (433, 434, 435, 436, 374, 379, 380, 384) bolt locations. Notice Failure to use the parts in the service kit as instructed will cause improper function, and possible transmission distress. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: Customer Interest A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 4548 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 4549 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest for Clutch: > 08-07-30-009B > May > 08 > A/T 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 06-07-30-023C > Oct > 09 > A/T - 4T65E 1-2 Shift Shudder On Light Acceleration Clutch: All Technical Service Bulletins A/T - 4T65E 1-2 Shift Shudder On Light Acceleration TECHNICAL Bulletin No.: 06-07-30-023C Date: October 15, 2009 Subject: 4T65E Transmission 1-2 Shift Shudder at Light to Moderate Acceleration (Replace Complete Second Clutch Assembly) Models: 2001-2004 Buick Regal 2001-2005 Buick Century, LeSabre 2002-2007 Buick Rendezvous 2005-2007 Buick Terraza, LaCrosse, Allure (Canada Only) 2006-2007 Buick Lucerne 2001-2005 Chevrolet Venture 2001-2007 Chevrolet Impala, Monte Carlo 2005-2007 Chevrolet Uplander 2006-2007 Chevrolet Malibu SS, Malibu Maxx SS 2001-2002 Oldsmobile Intrigue 2001-2003 Oldsmobile Aurora 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Bonneville, Montana 2001-2007 Pontiac Grand Prix 2005-2007 Pontiac Montana SV6 2006-2007 Pontiac G6 GTP 2005-2007 Saturn Relay with 4T65E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to update parts information. Please discard Corporate Bulletin Number 06-07-30-023B (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a 1-2 shift shudder at light to moderate acceleration. Typically, the throttle plate angle parameter is 12-20% at time of condition with vehicle speed of approximately 24-40 km/h (15-25 mph). The customer may describe the condition as slip or delayed shift into second. Correction Replace the complete second clutch assembly with service kit, P/N 24240561. Refer to the GM Unit Repair Service Manual for the year and model of the vehicle being serviced for the 2nd Clutch service procedure. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 06-07-30-023C > Oct > 09 > A/T - 4T65E 1-2 Shift Shudder On Light Acceleration > Page 4559 This service kit contains: Second Clutch Housing Fluid Seal Rings (613), a Second Clutch Assembly (617), a Case Cover (Channel Plate) Upper Gasket (430), and a Case Cover (Channel Plate) Lower Gasket (429). In addition to the content of this service kit, other gaskets not included in this service kit will also be needed to complete the repair - a Case Cover Lower Gasket (429), and a Case Cover Upper Gasket (430). These gaskets can be obtained by ordering gasket kit 24206391. Be sure to use ONLY the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings provided in this service kit. DISCARD the Second Clutch Assembly and Second Clutch Housing Fluid Seal Rings removed from the transmission being serviced. Disassemble ONLY the Oil Pump Assembly from the Case Cover (Complete). DO NOT disassemble the Control Valve Body from the Case Cover. Remove ONLY the Case Cover-to-Case bolts to remove the Case Cover and Valve Body from Transmission Case AS AN ASSEMBLY. To access all Case Cover-to-Case bolts, it is necessary to remove the Pressure Control Solenoid Valve Assembly (322), and 1-2 & 3-4 Shift Solenoid Valve Assemblies (315A, 315B). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 06-07-30-023C > Oct > 09 > A/T - 4T65E 1-2 Shift Shudder On Light Acceleration > Page 4560 Important This service kit does not contain the gaskets and/or seals necessary to service the Case Cover and Control Valve Body, if they are disassembled from each other. Please review the graphic above for Pump Body-to-Case (230), Pump Cover-to-Case (231), Control Valve Body-to-Case (377), Manual Shift Detent Assembly-to-Case (805), and Case Cover-to-Case (433, 434, 435, 436, 374, 379, 380, 384) bolt locations. Notice Failure to use the parts in the service kit as instructed will cause improper function, and possible transmission distress. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear Clutch: All Technical Service Bulletins A/T - No Movement in Drive or 3rd Gear TECHNICAL Bulletin No.: 08-07-30-027 Date: June 04, 2008 Subject: No Movement When Transmission is Shifted to Drive or Third - Normal Operation When Shifted to Second, First or Reverse (Replace Forward Sprag Assembly) Models: 1982 - 2005 GM Passenger Cars and Light Duty Trucks 2006 - 2007 Buick Rainier 2006 Cadillac Escalade, Escalade ESV, Escalade EXT 2006 Chevrolet SSR 2006 - 2008 Chevrolet Avalanche, Colorado, Express, Silverado Classic, Silverado, Suburban, Tahoe, TrailBlazer 2006 GMC Yukon Denali, Yukon Denali XL 2006 - 2008 GMC Canyon, Envoy, Savana, Sierra Classic, Sierra, Yukon, Yukon XL 2006 Pontiac GTO 2006 - 2007 HUMMER H2 2006 - 2008 HUMMER H3 2006 - 2008 Saab 9-7X with 4L60, 4L60E, 4L65E or 4L70E Automatic Transmission (RPOs MD8, M30, M32, M33 or M70) Condition Some customers may comment that the vehicle has no movement when the transmission is shifted to DRIVE or THIRD position, but there is normal operation when it is shifted to SECOND, FIRST or REVERSE position. Cause This condition may be caused by a damaged forward sprag assembly (642). Correction When inspecting the sprag, it is important to test the sprag for proper operation by holding the outer race (644) with one hand while rotating the input sun gear (640) with the other hand. The sun gear should rotate only in the counterclockwise direction with the input sun gear facing upward. If the sprag rotates in both directions or will not rotate in either direction, the sprag elements should be inspected by removing one of the sprag assembly retaining rings (643). Refer to SI Unit Repair section for forward clutch sprag disassembly procedures. If the sprag is found to be damaged, make repairs to the transmission as necessary. A new forward roller clutch sprag assembly is now available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 4565 If clutch debris is found, it is also very important to inspect the Pressure Control (PC) solenoid valve (377) fluid screens. Clean or replace the PC solenoid (377) as necessary. It is also important to flush and flow check the transmission oil cooler using J45096. Refer to SI Automatic Transmission Oil Cooler Flushing and Flow Test for the procedure. The notches above each sprag must point up as shown when assembled into the outer race. Bearing Assembly, Input Sun Gear Snap Ring, Overrun Clutch Hub Retaining Hub, Overrun Clutch Wear Plate, Sprag Assembly Retainer and Race Assembly, Sprag Forward Sprag Assembly Retainer Rings, Sprag Assembly Outer Race, Forward Clutch Washer, Thrust (Input Carrier to Race) The following information applies when this sprag is used in 1982-86 transmissions. The new design sprag can be used on models 1982 through 1986, by replacing the entire assembly (637 - 644). Individual components are NOT Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-027 > Jun > 08 > A/T - No Movement in Drive or 3rd Gear > Page 4566 interchangeable. Important: The wear plate (640) and input thrust washer (660) are not required with the new sprag. Use of the thrust washer and wear plate with the new sprag assembly will cause a misbuild (correct end play cannot be obtained). Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Clutch: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair Differential: Service and Repair Final Drive Replacement Tools Required ^ J 42562 Axle Removal Wedge Removal Procedure 1. Remove the case extension housing. 2. Remove the left drive axle from the transaxle. 3. Rotate the differential carrier until the end of the output shaft can be seen and the differential pinion shaft (701) is in a horizontal position. 4. Place the J 42562 between the end of the output shaft and the differential pinion shaft. 5. Using a hammer, hit the end of the axle removal tool in order to compress the output shaft compression ring (512) and push the output shaft through the differential side gear. 6. Remove the differential carrier (700). 7. Using snap ring pliers remove the compression ring (512) from the output shaft. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Page 4574 8. Remove the output shaft (510) through the left wheel opening. 9. Inspect the output shaft (510). 10. Remove the sun gear thrust bearing (698) from the differential carrier sun gear. The bearing may be stuck to the differential carrier. 11. Remove the differential carrier sun gear (697). 12. Remove the park gear (696). 13. Remove the internal gear thrust bearing (695) from the differential carrier internal gear. 14. Remove the sun gear shaft (689). 15. Inspect the differential carrier. Installation Procedure 1. Assemble the sun gear thrust bearing (698), the differential carrier sun gear (697), the park gear (696), the internal gear thrust bearing (695) and the sun gear shaft (689) into the differential carrier (700). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic Transaxle > Component Information > Service and Repair > Page 4575 2. Install the differential carrier into the case. 3. Install the drive axle retainer rings (509) to the output shaft (510). 4. Hold the front differential carrier in place and carefully install the output shaft to the transmission through the left wheel opening. 5. Install the case extension housing. 6. Install left drive axle to the transaxle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair Automatic Transmission Dipstick - Dipstick Tube: Service and Repair Fluid Filler Tube Replacement Removal Procedure 1. Remove the transaxle oil level indicator. 2. Raise and support the vehicle. 3. Remove the catalytic converter from the exhaust manifold. 4. Remove the fluid filler tube bracket bolt. 5. Remove the fluid filler tube. Installation Procedure Important: Do NOT place the fluid filler tube seal on the fluid filler tube when installing the tube or damage to the seal will result. 1. Install the fluid filler tube seal in the transaxle. 2. Position the fluid filler tube. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the fluid filler tube bracket bolt. Tighten the bolt to 13 Nm (115 inch lbs.). 4. Install the catalytic converter. 5. Lower the vehicle. Notice: Refer to Do Not Overfill the Transmission Notice. 6. Check and fill the transaxle as necessary. 7. Install the transaxle oil level indicator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Automatic Transmission Dipstick - Dipstick Tube > Component Information > Service and Repair > Page 4579 8. Inspect for fluid leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair Extension Housing: Service and Repair Case Extension Housing Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Raise and support the vehicle. 3. Remove the right drive axle from the transaxle. 4. Remove the transaxle brace. 5. Remove the vehicle speed sensor. 6. Remove the case extension housing bolts (5). 7. Remove the case extension housing (6) with the axle seal and the O-ring (8). 8. Inspect the case extension (6). Installation Procedure 1. If removed, install the drive axle seal. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair > Page 4583 2. Install the O-ring (8) to the case extension housing (6). 3. Install the case extension housing (6) with the axle seal and the O-ring (8). Notice: Refer to Fastener Notice in Service precautions. 4. Install the case extension housing bolts (5). Tighten the bolts to 36 Nm (27 ft. lbs.). 5. Install the vehicle speed sensor. 6. Install the transaxle brace. 7. Install the right drive axle to the transaxle. 8. Lower the vehicle. 9. Connect the negative battery cable. Notice: Refer to Do Not Overfill the Transmission Notice. 10. Check and fill the transaxle as necessary. 11. Inspect for fluid leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information Fluid - A/T: Technical Service Bulletins A/T - DEXRON(R)-VI Fluid Information INFORMATION Bulletin No.: 04-07-30-037E Date: April 07, 2011 Subject: Release of DEXRON(R)-VI Automatic Transmission Fluid (ATF) Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2007 Saturn Relay 2005 and Prior Saturn L-Series 2005-2007 Saturn ION 2005-2008 Saturn VUE with 4T45-E 2005-2008 Saab 9-7X Except 2008 and Prior Chevrolet Aveo, Equinox Except 2006 and Prior Chevrolet Epica Except 2007 and Prior Chevrolet Optra Except 2008 and Prior Pontiac Torrent, Vibe, Wave Except 2003-2005 Saturn ION with CVT or AF23 Only Except 1991-2002 Saturn S-Series Except 2008 and Prior Saturn VUE with CVT, AF33 or 5AT (MJ7/MJ8) Transmission Only Except 2008 Saturn Astra Attention: DEXRON(R)-VI Automatic Transmission Fluid (ATF) is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids. Supercede: This bulletin is being revised to update information. Please discard Corporate Bulletin Number 04-07-30-037D (Section 07 - Transmission/Transaxle). MANUAL TRANSMISSIONS / TRANSFER CASES and POWER STEERING The content of this bulletin does not apply to manual transmissions or transfer cases. Any vehicle that previously required DEXRON(R)-III for a manual transmission or transfer case should now use P/N 88861800. This fluid is labeled Manual Transmission and Transfer Case Fluid. Some manual transmissions and transfer cases require a different fluid. Appropriate references should be checked when servicing any of these components. Power Steering Systems should now use P/N 9985010 labeled Power Steering Fluid. Consult the Parts Catalog, Owner's Manual, or Service Information (SI) for fluid recommendations. Some of our customers and/or General Motors dealerships/Saturn Retailers may have some concerns with DEXRON(R)-VI and DEXRON(R)-III Automatic Transmission Fluid (ATF) and transmission warranty claims. DEXRON(R)-VI is the only approved fluid for warranty repairs for General Motors transmissions/transaxles requiring DEXRON(R)-III and/or prior DEXRON(R) transmission fluids (except as noted above). Please remember that the clean oil reservoirs of the J-45096 - Flushing and Flow Tester machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI for testing, flushing or filling General Motors transmissions/transaxles (except as noted above). DEXRON(R)-VI can be used in any proportion in past model vehicles equipped with an automatic transmission/transaxle in place of DEXRON(R)-III (i.e. topping off the fluid in the event of a repair or fluid change). DEXRON(R)-VI is also compatible with any former version of DEXRON(R) for use in automatic transmissions/transaxles. DEXRON(R)-VI ATF General Motors Powertrain has upgraded to DEXRON(R)-VI ATF with the start of 2006 vehicle production. Current and prior automatic transmission models that had used DEXRON(R)-III must now only use DEXRON(R)-VI. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 4588 All 2006 and future model transmissions that use DEXRON(R)-VI are to be serviced ONLY with DEXRON(R)-VI fluid. DEXRON(R)-VI is an improvement over DEXRON(R)-III in the following areas: * These ATF change intervals remain the same as DEXRON(R)-III for the time being. 2006-2008 Transmission Fill and Cooler Flushing Some new applications of the 6L80 six speed transmission will require the use of the J 45096 Flushing and Flow Tester to accomplish transmission fluid fill. The clean oil reservoir of the machine should be purged of DEXRON(R)-III and filled with DEXRON(R)-VI. Parts Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 4589 Fluid - A/T: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - DEXRON(R)-VI Fluid Information > Page 4590 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications Fluid - A/T: Capacity Specifications Transmission Fluid Pan Removal ........................................................................................................ ............................................................................................. 7.0L (7.4 Qt) Overhaul ........................... .............................................................................................................................................................. ................. 9.5L (10.0 Qt) Dry .............................................................................................................. .................................................................................................. 12.7L (13.4 Qt) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Capacity Specifications > Page 4593 Fluid - A/T: Fluid Type Specifications Transmission Fluid Type Type ..................................................................................................................................................... ...................................... DEXRON III or Equivalent Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair Fluid Filter - A/T: Service and Repair Oil Filter and Seal Replacement Removal Procedure 1. Remove the oil pan (24) and the gasket (25). 2. Remove the filter (100). Remove the lip ring seal (101) pressed into the case only if replacement is necessary. 3. Inspect the oil pan and the filter for the following foreign material: ^ metal particles ^ clutch facing material ^ rubber particles ^ engine coolant 4. Determine the source of the contamination if foreign material is evident. 5. Correct the source of the contamination. Installation Procedure 1. If removed, install a new seal (101). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T > Component Information > Service and Repair > Page 4597 2. Install the filter (100). 3. Install the gasket (25) and the oil pan (24). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Fluid Line/Hose: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 4602 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement Fluid Line/Hose: Service and Repair Transmission Fluid Cooler Hose/Pipe Replacement Transmission Fluid Cooler Hose/Pipe Replacement Removal Procedure Notice: Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to prevent damage or wear which may cause fluid loss. 1. Raise and support the vehicle. 2. Position the drain pan under the transaxle. 3. Remove the lower radiator air deflector. Important: Perform the following procedures when removing the retaining ring and the oil cooler pipe from the quick connect fitting on the transmission. 4. Pull the plastic cap back from the quick connect fitting and down along the oil cooler pipe about two inches. 5. Using a bent-tip screwdriver, pull on one of the open ends of the retaining ring in order to rotate the retaining ring around the quick connect fitting until the retaining ring is out of position and can be completely removed. 6. Remove the retaining ring from the quick connect fitting. 7. Discard the retaining ring. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4605 8. Remove the retaining bracket bolt (5) from the transaxle oil cooler hose/pipe retaining bracket (1). 9. Remove the oil cooler pipes (3-4) from the oil cooler fittings (2). 10. Remove the oil cooler pipes from the fittings at the radiator. 11. Remove the oil cooler hose/pipes from the retaining clip. 12. Remove the oil cooler hose/pipes from the vehicle. Installation Procedure Important: Do not reuse any of the existing retaining rings that were removed from the existing quick connect fittings. Install NEW retaining rings. 1. Install a new retaining ring into the quick connect fitting using the following procedure. 2. Hook one of the open ends of retaining ring into one of the slots in the quick connect fitting. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4606 3. Rotate the retaining ring around the fitting until the ring is positioned with all 3 ears through the 3 slots on the fitting. 4. Do not install the new retaining ring onto the fitting by pushing the retaining ring. 5. Ensure that the 3 ears are seen from inside the fitting and that the ring moves freely in the fitting slots. 6. Install the new retaining ring into the remaining quick connect fittings. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4607 7. Install the oil cooler hose/pipes to the retaining clip. Notice: Ensure that the cooler line being installed has a plastic cap on each end that connects to a quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new plastic cap and position on to the cooler line prior to the cooler line installation. Important: Do not use the plastic cap to install the oil cooler pipe into the fitting. 8. Install the oil cooler pipe into the quick connect fitting at the radiator. 9. Insert the oil cooler pipe end into the quick connect fitting until a click is either heard or felt. 10. Pull back sharply on the oil cooler pipe in order to ensure that the pipe is fastened into the quick connect fitting. 11. Install the plastic cap onto the fitting. Do not manually depress the retaining ring when installing the cap onto the fitting. 12. Ensure that the cap is fully seated against the fitting. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4608 13. Ensure that no gap is present between the cap and the fitting. 14. Ensure that the yellow identification band on the tube is hidden within the quick connect fitting. A hidden yellow identification band indicates proper joint seating. 15. Install the oil cooler pipes (3, 4) to the oil cooler fittings (2). Notice: Refer to Fastener Notice in Service Precautions. 16. Install the transaxle oil cooler hose/pipes retaining bracket bolt (5). Tighten the bolt to 4 Nm (27 inch lbs.). 17. Install the lower radiator air deflector. 18. Remove the drain pan from under the vehicle. 19. Lower the vehicle. Notice: Refer to Transmission Overfill Notice. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4609 20. Adjust the fluid level. 21. Inspect for proper completion of the repairs. 22. Inspect for fluid leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4610 Fluid Line/Hose: Service and Repair Transmission Oil Cooler Line Quick Connect Fitting Transmission Oil Cooler Line Quick Connect Fitting Removal Procedure 1. Disengage the plastic cap from the quick connect fitting. Pull the plastic cap back along the pipe. 2. Hold one leg of the retaining clip. 3. Using a small pick-type tool or bent screwdriver, gently disengage the other end of the retaining clip from the quick connect fitting. 4. Rotate the retaining clip out of the quick connect fitting. Remove the retaining clip completely. 5. Disconnect the cooler line from the quick connect fitting. Installation Procedure Important: Failure to properly install the retaining clip could cause the cooler line to come loose and cause damage to vehicle components. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4611 1. Do NOT install the retaining clip onto the fitting by pushing on the clip. 2. Install the retaining clip into the quick connect fitting by using your thumb and forefinger. Insert the retaining clip into one of the three fitting recesses. Ensure that the retaining clip is engaged in all 3 slots. 3. With one end of the retaining clip engaged in the connector fitting slot, use your thumb in order to rotate the retaining clip around the connector fitting, until the retaining clip snaps into place. 4. Ensure that the 3 retaining clip ears are seen from inside the fitting and that the retaining clip moves freely in the fitting slots. Important: A distinct snap should be heard when assembling the cooler line to the quick connect fitting. To ensure the cooler line is fully inserted into the quick connect fitting, give the cooler line a gentle pull. Do not use the plastic cap in order to install the cooler line into the fitting. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Service and Repair > Transmission Fluid Cooler Hose/Pipe Replacement > Page 4612 5. Install the cooler line straight into the quick connect fitting until a click is either heard or felt. 6. Pull back gently on the cooler line in order to ensure that the cooler line is installed in the quick connect fitting. Important: Ensure the cooler line being installed has a plastic cap on the end that connects to the quick connect fitting. If no plastic cap exists, or the plastic cap is damaged, obtain a new cap. Install the cap on to the cooler line prior to cooler line installation. Do not manually depress the retaining clip when installing the plastic cap. 7. Snap the plastic cap onto the quick connect fitting. 8. Ensure that the plastic cap is fully seated against the fitting. 9. Ensure that no gap is present between the cap and the fitting. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications Fluid Pan: Specifications Oil pan bolts ......................................................................................................................................... .................................................... 14 Nm (10 ft. lbs.) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4616 Fluid Pan: Service and Repair Oil Pan Replacement Removal Procedure Notice: Do NOT use any type of grease to retain parts during the assembly of this unit. Using greases other than the recommended assembly lube changes the transaxle fluid characteristics. Using greases other than the recommended assembly lube causes undesirable shift conditions and/or filter clogging. Use TRANSJEL J 36850 or equivalent during the assembly of this unit. 1. Raise and support the vehicle. 2. Place a drain pan under the transaxle oil pan. 3. Remove the transaxle oil pan bolts (23) from the front and the sides of the oil pan. 4. Loosen the rear transaxle oil pan bolts. Notice: Ensure care is taken NOT to damage the mating surfaces of the oil pan and of the case or oil leaks may occur. 5. Use a rubber mallet to lightly tap the oil pan or use a screwdriver to pry the oil pan loose. 6. Allow the fluid to drain. 7. Remove the remaining transaxle bolts (23). 8. Remove the oil pan (24) from the automatic transmission. 9. Remove the oil pan gasket (25). 10. Inspect the oil pan and the filter for the following foreign material: ^ Metal particles ^ Clutch facing material ^ Rubber particles ^ Engine coolant 11. Determine the source of the contamination. 12. Correct the source of the contamination. 13. Inspect the oil pan flange (1) for distortion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4617 14. Replace the oil pan (1) if bent or distorted. Do not attempt to straighten. 15. When service requires the removal of the bottom oil, inspect the washers on the oil pan bolts. 16. If the washer is inverted, replace the bolt and the washer. Notice: Ensure the oil pan and the case flanges are dry and are free of any oil film or leakage may result. 17. Use solvent to clean the case. 18. Air dry the case. 19. Use solvent to clean the oil pan gasket surfaces. 20. Air dry the oil pan gasket surfaces. 21. Remove all traces of the old gasket material. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Specifications > Page 4618 1. Install the oil pan gasket (25). 2. Install the oil pan (24). Notice: Refer to Fastener Notice in Service precautions. 3. Install the oil pan bolts (23). Tighten the bolts to 14 Nm (10 ft. lbs.). 4. Lower the vehicle. Notice: Refer to Do Not Overfill the Transmission Notice. 5. Fill the transaxle with DEXRON III. 6. Place the gear selector in the Park position. 7. Start the engine. 8. Run the engine at a slow idle. Do NOT race the engine. 9. Adjust the fluid level. 10. Inspect for leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4622 Automatic Transmission Fluid Pressure Manual Valve Position Switch Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4623 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the transaxle wiring harness. 3. Remove the control valve body bolts (375, 379, 381) that mount the fluid pressure manual valve position switch to the control valve body (300). Important: When removing the TFP switch handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 4. Carefully remove the fluid pressure manual valve position switch (395) 5. Inspect the fluid pressure manual valve position switch (395) for the following conditions ^ Damaged electrical connector terminals ^ Damaged seals ^ Damaged switch membranes ^ Debris on the switch membranes Installation Procedure Important: When installing the TFP switch handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 1. Carefully install the fluid pressure manual valve position switch (395). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the control valve body bolts (375, 379, 381) that mount the TFP switch to the control valve body (300). ^ Tighten the control valve body bolt (375) to 12 Nm (106 inch lbs.). ^ Tighten the control valve body bolt (379) to 16 Nm (106 inch lbs.). ^ Tighten the control valve body bolt (381) to 8 Nm (70 inch lbs.). 3. Connect the transaxle wiring harness. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4624 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Fluid Pump: Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4629 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4630 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4631 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4632 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4633 Fluid Pump: Technical Service Bulletins A/T - 4L65E, 4L60E, 4L60, 200-4R Oil Pump Spring Bulletin No.: 04-07-30-006 Date: February 11, 2004 INFORMATION Subject: 4L65-E, 4L60-E, 4L60 and 200-4R Automatic Transmission Oil Pump Spring First and Second Design Identification Models: 2004 and Prior Passenger Cars and Light Duty Trucks 2003-2004 HUMMER H2 with 4L65-E, 4L60-E, 4L60 or 200-4R Automatic Transmission The purpose of this bulletin is to identify the oil pump spring usage for the two different pump designs. Manufacturing of the first design oil pump springs ended December 15, 2003. Manufacturing of the second design oil pump spring began December 16, 2003 The first design oil pump springs (206) and (207) DO NOT have any identification markings. The first design springs (206) and (207) use an inner and outer spring, two springs. The second design oil pump spring (245) is identified with tapered ends on the spring (245) as shown above. The second design spring (245) is a single spring. When servicing either (first design or second design) oil pump body, use the new single oil pump spring (245) with tapered ends. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Technical Service Bulletins > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4634 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators A/T > Shift Indicator > Component Information > Diagrams PRNDL Lamp Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Maintenance Indicator A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise Output Shaft: Technical Service Bulletins A/T - 2-3 Upshift or 3-2 Downshift Clunk Noise INFORMATION Bulletin No.: 01-07-30-042F Date: February 05, 2010 Subject: Information on 2-3 Upshift or 3-2 Downshift Clunk Noise Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X with 4L60-E, 4L65-E or 4L70-E Automatic Transmission (RPOs M30, M32, M70) Supercede: This bulletin is being revised to add the 2010 model year and 4L70E transmission. Please discard Corporate Bulletin Number 01-07-30-042E (Section 07 - Transmission/Transaxle). Important For 2005 model year fullsize utilities and pickups, refer to Corporate Bulletin 05-07-30-012. Some vehicles may exhibit a clunk noise that can be heard on a 2-3 upshift or a 3-2 downshift. During a 2-3 upshift, the 2-4 band is released and the 3-4 clutch is applied. The timing of this shift can cause a momentary torque reversal of the output shaft that results in a clunk noise. This same torque reversal can also occur on a 3-2 downshift when the 3-4 clutch is released and the 2-4 band applied. This condition may be worse on a 4-wheel drive vehicle due to the additional tolerances in the transfer case. This is a normal condition. No repairs should be attempted. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > Page 4649 Output Shaft: Service and Repair Output Shaft Replacement Tool Required ^ J 42562 Axle Removal Wedge Removal Procedure 1. Remove the case extension housing. 2. Remove the left drive axle from the transaxle. 3. Rotate the differential carrier until the end of the output shaft can be seen and the differential pinion shaft (701) is in a horizontal position. 4. Place the J 42562 between the end of the output shaft and the differential pinion shaft. 5. Using a hammer, hit the end of the axle removal tool in order to compress the output shaft compression ring (512) and push the output shaft through the differential side gear. 6. Remove the differential carrier (700). 7. Using snap ring pliers remove the compression ring (512) from the output shaft. 8. Remove the output shaft through the left wheel opening. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > Page 4650 9. Inspect the output shaft (510) for the following: ^ Stripped splines ^ Damaged retainer ring groove ^ Damaged bushing journals Installation Procedure 1. Install the drive axle retainer rings (509) to the output shaft (510). 2. Hold the front differential carrier in place and carefully install the output shaft (510) to the transmission through the left wheel opening. Extend the output shaft through the differential side gear. 3. Install the case extension housing. 4. Install the left drive axle to the transaxle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft Bearing/Bushing, A/T > Component Information > Technical Service Bulletins > A/T - 4T65-E Final Drive Assembly Precaution Output Shaft Bearing/Bushing: Technical Service Bulletins A/T - 4T65-E Final Drive Assembly Precaution Bulletin No.: 04-07-30-030 Date: July 02, 2004 INFORMATION Subject: Using Caution When Servicing Final Drive Unit on 4T65-E Transaxles To Insure Internal Gear Thrust Bearing (695) is Properly Seated/Located Models: 2001-2005 GM Passenger Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) When servicing a final drive unit on a 4T65-E transaxle, use extreme caution to ensure that the internal gear thrust bearing (695) is properly seated/located. It has been found that after servicing a final drive unit on 4T65-E transaxles, the internal gear thrust bearing (695) was not properly seated/located causing internal damage and a repeat repair. Use a generous amount of Transgel J 36850 when installing the internal gear thrust bearing (695) to the park gear (696) to ensure the internal thrust bearing (695) will retain its proper position during assembly. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments Parking Lock Cable: Adjustments Park Lock Cable Adjustment 1. Place the shift lever in the PARK position. 2. Place the ignition key in the LOCK position. 3. Ensure the shift lever cannot move to another position. The ignition key should be removable from the ignition lock cylinder. 4. Place the ignition key in the RUN position. 5. Place the shift lever in the NEUTRAL position. 6. Ensure that the ignition key cannot turn to the LOCK position. 7. The system is properly adjusted if the above conditions are met. Proceed to step 13. 8. If the above conditions are not met proceed with the adjustment procedure. 9. Pull the cable connector lock back to the UP position. 10. Adjust the cable connector as outlined. 10.1. Push the cable connector nose forward to remove the slack. 10.2. Push the cable connector lock button down. 11. Check the operation. 12. If the ignition key cannot be removed in the PARK position, then pull the connector lock button to the UP position. 13. Move the cable connector nose rearward until the key can be removed from the ignition. 14. Push the lock button down. 15. Install the cable into the clips to provide the correct routing. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > Page 4658 Parking Lock Cable: Service and Repair Park Lock Cable Replacement Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the console. 3. Remove the knee bolster bracket. 4. Place the transaxle shift control lever in the PARK position. Important: Ensure the ignition key is in the RUN position. Do NOT attempt to proceed to Step 6 with the key in any other position. 5. Turn the ignition key to the RUN position. 6. Slip a screwdriver blade into the slot provided in the ignition switch inhibitor. 7. Use the screwdriver to depress the cable latch. 8. Pull the cable from the inhibitor. 9. Remove the park/lock cable from the shift control. 10. Remove the cable retainer from the park/lock cable at the shift control. 11. Remove the park/lock cable. Installation Procedure 1. Ensure the cable lock button is in the UP position. 2. Ensure the shift lever is in the PARK position. 3. Install the park/lock cable. 4. Snap the cable connector into the shifter base. 5. Install the cable retainer to park/lock cable to the shift control. 6. Ensure the ignition key is in the RUN position. 7. Install the cable into the inhibitor housing. Important: Ensure the ignition key is in the LOCK position. Do NOT attempt to insert the cable with the key in any other position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Lock Cable, A/T > Component Information > Adjustments > Page 4659 8. Turn the ignition key to the LOCK position. 9. Install the cable end onto the shifter park lock lever pin. 10. Push the cable connector nose forward to remove the slack. 11. Push the cable connector lock button down using no load applied to the connector nose. 12. Inspect the operation of the park/lock cable for proper adjustment. 13. Install the console. 14. Install the knee bolster bracket. 15. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Technical Service Bulletins > A/T - Grinding/Growling Noise in Park on Incline Parking Pawl: Technical Service Bulletins A/T - Grinding/Growling Noise in Park on Incline INFORMATION Bulletin No.: 99-07-30-030F Date: May 01, 2008 Subject: Grinding and/or Growling Noise in Park on Incline Models: 2009 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) with Hydra-Matic Front Wheel Drive (FWD) Automatic Transmissions Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 99-07-30-030E (Section 07 - Transmission/Transaxle). Service Information Owners of some vehicles equipped with Hydra-Matic front wheel drive transaxles may comment on a grinding and/or growling noise that is noticeable when standing in PARK on a hill or slope with the engine running and the parking brake not applied. Under these conditions, the weight of the vehicle puts a load on the parking pawl which can create a "ground-out" path through the drive axles, front struts, springs and spring towers. Normal engine noise can be transmitted to the passenger compartment through the "ground-out" path. Owners concerned about this condition should be advised to apply the parking brake prior to shifting into PARK. This is the recommended procedure described in the Owners Manual. Applying the parking brake first will put the load of the vehicle on the rear brakes rather than on the parking pawl. Refer the owner to the appropriate Owner Manual for additional details and instructions. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4667 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 4668 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid (PCS) Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the Pressure Control Solenoid (PCS) electrical connector. 3. Remove the PCS retaining clip (314E). 4. Remove the PCS (322). Installation Procedure 1. Install the PCS (322). 2. Install the PCS retaining clip (314E). 3. Connect the PCS electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: Customer Interest A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > Customer Interest: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 4677 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent Seals and Gaskets: All Technical Service Bulletins A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 01-07-30-032E > Sep > 08 > A/T - 4T65E Fluid Leaking From A/T Vent > Page 4683 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4688 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4689 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4690 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4691 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Seals and Gaskets: All Technical Service Bulletins A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service Bulletin No.: 04-07-30-023 Date: May 12, 2004 INFORMATION Subject: Oil Pump Assembly Seal and Transmission Case Change Models: 2002-2004 Cars and Light Duty Trucks with 4L60-E or 4L65-E Automatic Transmissions (RPOs M30, M32 or M33) An improved oil pump to case seal design has been made to the 4L60-E/4L65-E transmission. The new design affects the oil pump, the oil pump seal, the transmission pan bolts and the transmission case. The complete design was implemented in three phases. The first phase, beginning in September 2002, relocated the machining of the oil pump 0-ring seal groove in the pump body. The 0-ring seal groove moved 1.6 mm (0.62 in) inward on the pump body in order to place the sealing surface deeper into the case bore. The relocated pump body groove can be identified by measuring the groove location. Pump bodies that measure 2.3 mm (0.09 in) from the machined surface to the groove opening have the relocated 0-ring seal groove. Pump bodies that measure 3.9 mm (0.15 in) are prior to September 2002 design. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4697 The first phase also machined a case chamfer leading into the pump bore (2). The chamfer is designed to help eliminate possible 0-ring seal damage during pump installation. Phase two modified the case casting and the chamfer into the pump bore. The casting change left additional material in the surrounding pump bore to allow deeper bore machining in order to create the necessary sealing surface for a new pump seal design. The leading surface into the pump bore was also machined with a modified chamfer (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4698 Phase three will eliminate the oil pump body 0-ring seal groove and the 0-ring seal. Beginning March 2004, a new stamped carrier molded rubber seal (2) will be used to seal the pump assembly to the transmission case. The pump sealing surface is now the outer diameter of the pump and the inner diameter (1) of the transmission case bore. Unlike the current 0-ring seal, which is installed on the oil pump body, the new seal is installed after the pump assembly is properly positioned and torqued in place. Seating the seal is accomplished when the torque converter housing is installed, which presses the seal (3) into position between the pump and the case bore (1). As a result of the modified casting and the deeper pump bore machining, the area between the oil pan mounting surface and the pump bore has decreased. Because of the reduced material in this area (1) it is necessary to use the shorter oil pan attaching bolts (2). Early pan bolts (3), before November 2002, should not be used with the modified case design, since they are 1.0 mm (0.39 in) longer and could deform the chamfer surface (4). Service Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4699 When Servicing transmissions with the new seal design, use the following precautions: ^ The outer diameter of the pump assembly and case bore must be clean and free of burrs or raised surfaces. Be aware of sharp edges that could damage the seal during installation. ^ The seal should be clean and dry before installation. It does not require lubrication for installation. ^ The seal should be inspected prior to installation for obvious damage. ^ It is preferable to hand-start the seal positioning the seal evenly around the case bore before installing the torque converter housing. ^ The seal can be easily removed by prying it out, typical of a pressed-on seal. ^ The seal may be reused, however a thorough inspection must be performed. Inspect the seal for the following conditions: ^ Distortion of the metal carrier or separation from the rubber seal. ^ A cut, deformed, or damaged seal. ^ Refer to the appropriate unit repair information in SI for seal removal and installation procedures. Parts Interchangeability Information In order to properly service the different designs, it is necessary to correctly identify and select corresponding parts for each level. This table provides a summary of the part usage for the different design levels. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 04-07-30-023 > May > 04 > A/T - 4L60-E/4L65-E New Pump/Seal/Case/Service > Page 4700 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4701 Seals and Gaskets: By Symptom Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4702 For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 01-07-30-032E Date: 080929 A/T - 4T65E Fluid Leaking From A/T Vent TECHNICAL Bulletin No.: 01-07-30-032E Date: September 29, 2008 Subject: Transmission Oil Leaking From Transmission Vent (Replace Transmission Case Cover (Channel Plate) Gasket) Models: 1997-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) with Hydra-Matic 4T65-E Automatic Transmission (RPOs MN3, MN7, M15, M76) Supercede: This bulletin is being revised to add the 2008 and 2009 model years. Please discard Corporate Bulletin Number 01-07-30-032D (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak. Cause This condition may be caused by an improperly torqued channel plate gasket. Correction Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4703 To correct this condition, replace the case cover (channel plate) gaskets (429 and 430). Refer to Unit Repair publication in SI of the appropriate vehicle being serviced. Visual inspection of the upper gasket (1) will reveal damage at the referenced area. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Front Wheel Drive Shaft Oil Seal Replacement - Left Seals and Gaskets: Service and Repair Front Wheel Drive Shaft Oil Seal Replacement - Left Front Wheel Drive Shaft Oil Seal Replacement - Left Tools Required ^ J 34115 Left Side Axle Seal Installer ^ J 37292-B Axle Seal Protector Removal Procedure 1. Raise and support the vehicle. 2. Remove the left front tire and wheel. 3. Remove the left stabilizer shaft link from the left lower control arm. 4. Remove the left tie rod end from the left steering knuckle. 5. Remove the left lower ball joint from the left steering knuckle. 4. Remove the left drive axle from the transaxle. 7. Secure the left drive axle to the left steering knuckle and the strut. 8. Use a flat bladed screwdriver or a suitable tool to remove the oil seal (409) from the transaxle side case (401). Installation Procedure 1. Lubricate the seal lip with transaxle fluid. Important: Carefully guide the axle shaft past the lip seal. Do NOT allow the shaft splines to contact any portion of the seal lip surface. 2. Install J 37292-B in the seal (409). 3. Use J 34115 to install the new seal. 4. Remove the J 37292-B. 5. Install the drive axle to the transaxle. 6. Install the left lower ball joint to the left steering knuckle. 7. Install the left tie rod end to the left steering knuckle. 8. Install the left stabilizer shaft link to the left lower control arm. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Front Wheel Drive Shaft Oil Seal Replacement - Left > Page 4706 9. Install the left front tire and wheel. 10. Lower the vehicle. Notice: Refer to Do Not Overfill the Transmission Notice. 11. Adjust the fluid level. 12. Inspect for proper completion of the repairs. 13. Inspect for proper fluid level. 14. Inspect for fluid leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Front Wheel Drive Shaft Oil Seal Replacement - Left > Page 4707 Seals and Gaskets: Service and Repair Front Wheel Drive Shaft Oil Seal Replacement - Right Front Wheel Drive Shaft Oil Seal Replacement - Right Tools Required ^ J 6125-B Slide Hammer ^ J 23129 Universal Seal Remover ^ J 29130 Axle Shaft Seal Installer ^ J 37292-B Axle Seal Protector Removal Procedure 1. Raise and support the vehicle. 2. Remove the right front tire and wheel. 3. Remove the right stabilizer shaft link from the right lower control arm. 4. Remove the right tie rod end from the right steering knuckle. 5. Remove the right lower ball joint from the right steering knuckle. 6. Remove the right drive axle from the transaxle. 7. Secure the right drive axle to the right steering knuckle and the strut 8. Use the J 6125-B (3) and the J 23129 (4) to remove the oil seal (1) from the extension housing (2). Installation Procedure 1. Lubricate the seal lip with transaxle fluid. 2. Install J 37292-B in the seal (4). 3. Use J 29130 to install the new seal (4). 4. Remove the J 37292-B. Important: Carefully guide the axle shaft past the lip seal. Do NOT allow the shaft splines to contact any portion of the seal lip surface. 5. Install the drive axle to the transaxle. 6. Install the right lower ball joint to the right steering knuckle. 7. Install the right tie rod end to the right steering knuckle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T > System Information > Service and Repair > Front Wheel Drive Shaft Oil Seal Replacement - Left > Page 4708 8. Install the right stabilizer shaft link to the right steering knuckle. 9. Install the right front tire and wheel. 10. Lower the vehicle. Notice: Refer to Do Not Overfill the Transmission Notice. 11. Check and fill the transaxle fluid as necessary. 12. Inspect for fluid leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Brake Switch - TCC > Component Information > Diagrams TCC Brake Switch Wiring Harness Side C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4716 Automatic Transmission Fluid Pressure Manual Valve Position Switch Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4717 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the transaxle wiring harness. 3. Remove the control valve body bolts (375, 379, 381) that mount the fluid pressure manual valve position switch to the control valve body (300). Important: When removing the TFP switch handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 4. Carefully remove the fluid pressure manual valve position switch (395) 5. Inspect the fluid pressure manual valve position switch (395) for the following conditions ^ Damaged electrical connector terminals ^ Damaged seals ^ Damaged switch membranes ^ Debris on the switch membranes Installation Procedure Important: When installing the TFP switch handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 1. Carefully install the fluid pressure manual valve position switch (395). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the control valve body bolts (375, 379, 381) that mount the TFP switch to the control valve body (300). ^ Tighten the control valve body bolt (375) to 12 Nm (106 inch lbs.). ^ Tighten the control valve body bolt (379) to 16 Nm (106 inch lbs.). ^ Tighten the control valve body bolt (381) to 8 Nm (70 inch lbs.). 3. Connect the transaxle wiring harness. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 4718 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4722 Input Speed Sensor Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4723 Transmission Speed Sensor: Service and Repair Input Speed Sensor Replacement Removal Procedure 1. Remove the case side cover 2. Disconnect the input speed sensor electrical connector. 3. Remove the input speed sensor retaining clip (441). 4. Remove the input speed sensor (440). 5. Inspect the input speed sensor (440) for the following conditions: ^ Damaged or missing magnet ^ Damaged housing ^ Bent or missing electrical terminals ^ Damaged speed sensor clip (441) Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4724 1. Install the input speed sensor (440). 2. Install the input speed sensor retaining clip (441). 3. Connect the input speed sensor electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 4728 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 4729 Transmission Fluid Temperature Sensor Connector Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement Transmission Temperature Sensor/Switch: Service and Repair Thermo Element Replacement Thermo Element Replacement Tools Required ^ J 34094-A Thermo Element Height Gage Removal Procedure 1. Raise and support the vehicle. 2. Remove the oil pan. 3. Remove the thermo element pins (120, 123) and the washers. 4. Remove the thermo element (121) and the thermo element plate (122). Installation Procedure 1. Use the J 34094-A to set the middle thermo pin (123). 2. Install the new thermo element plate (122). 3. Install the pin (120) and the washer. 4. Use the J 34094-A to set the height of the pin and the washer furthest from the accumulator. 5. Use the J 34094-A to set the height of the second pin (120) and the washer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement > Page 4732 6. Install the thermo element (121) between the two pins (120). The V in the thermo element (121) must contact the thermo element plate (122). 7. Install the oil pan. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement > Page 4733 Transmission Temperature Sensor/Switch: Service and Repair Fluid Temperature Sensor Replacement Fluid Temperature Sensor Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the wiring harness assembly tram the fluid temperature sensor (391) 3. Remove the fluid temperature sensor (391). Installation Procedure 1. install the fluid temperature sensor (391). 2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Lower Center Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4738 Console And Center Of Floor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Locations > Page 4739 A/T Shift Lock Control Solenoid Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift Shift Interlock Solenoid: Service and Repair With Floor Shift Automatic Transmission Shift Lock Actuator Replacement (Floor Shift) Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the center console. 3. Disconnect the automatic shift lock actuator electrical connector. 4. Remove the automatic shift lock actuator from the pivot point (1), the base of the shift lock control and the vehicle. Installation Procedure 1. Install the automatic shift lock actuator to the base of the shift lock control and the pivot point (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift > Page 4742 2. Connect the automatic shift lock actuator electrical connector. 3. Install the center console. 4. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift > Page 4743 Shift Interlock Solenoid: Service and Repair With Column Shift Automatic Transmission Shift Lock Actuator Replacement (Column Shift) Removal Procedure 1. Remove the knee bolster bracket. 2. Disconnect the automatic shift lock actuator electrical connector. 3. Remove the actuator from the steering column ball studs. Installation Procedure 1. Install the automatic shift lock control actuator to the steering column ball studs. 2. Connect the automatic shift lock actuator electrical connector. 3. Place the column in the neutral position. 4. Adjust the automatic shift lock actuator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift > Page 4744 4.1. Pull out the tab (1) on the adjuster block side (2) of the actuator. 4.2. Press on the adjuster block (2) in order to compress the internal adjuster spring and disengage the adjuster teeth. Slide the adjuster block as far away from the actuator as possible. 4.3./105GLock in place by pushing in on the tab (1). 5. Inspect the actuator ^ The actuator must lock the shift lever clevis when you place the clevis in the park position. ^ If you can move the shift lever without pressing on the brake pedal. readjust the actuator. 6. Install the knee bolster bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid Valve State and Gear Ratio Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Specifications > Page 4748 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid Valve Connector, Wiring Harness Side > Page 4751 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the 1-2 shift solenoid electrical connector. 3. Remove the 1-2 shift solenoid retaining clip (314D) 4. Remove the 1-2 shift solenoid (315A). Installation Procedure 1. Install the 1-2 shift solenoid (315A). 2. Install the 1-2 shift solenoid retaining clip (314D). 3. Connect the 1-2 shift solenoid electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 4754 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the 2-3 shift solenoid electrical connector. 3. Remove the 2-3 shift solenoid retaining clip (314C). 4. Remove the 2-3 shift solenoid (315B) and the O-ring (316). Installation Procedure 1. Install the O-ring (316) and the 2-3 shift solenoid (315B). 2. Install the 2-3 shift solenoid retaining clip (314C). 3. Connect the 2-3 shift solenoid electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shifter A/T > Component Information > Service and Repair Shifter A/T: Service and Repair Shift Lever Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Slide the shift lever seal (2) up the shift lever (4). 3. If necessary, remove the steering column trim covers. 4. Disconnect the shift lever connector at the base of the column. 5. Remove the shift lever screw (3) from the shift lever assembly (4). 6. Remove the shift lever and seal from the column. Important: The shift lever seal must be removed by sliding the shift lever seal towards the narrow section of the shift lever. 7. Remove the shift lever seal (2) from the shift lever (4). Installation Procedure Important: The shift lever seal must be installed to the narrow end of the shift lever. 1. Install the shift lever seal (2) onto the shift lever assembly (4). 2. Install the shift lever assembly (4). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the shift lever screw (3) into the shift lever assembly (4). ^ Tighten the screw to 1.5 Nm (13 in. lbs.). 4. Slide the shift lever seal (2) down the shift lever assembly (4). 5. Align the shift lever seal into the steering column trim covers. 6. If necessary, install the steering column trim covers. 7. Enable the SIR system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments Shift Cable: Adjustments Automatic Transmission Range Selector Cable Adjustment Caution: Refer to Automatic Transaxle Range Selector Cable Caution. Notice: Adjust the automatic transaxle range selector cable while the transaxle and while the gear selector are in the Neutral position only. Failure to do so may cause mix-adjustment. 1. Set the parking brake. 2. Block the wheels. 3. Disconnect the shift cables at both ends with the system in Neutral. Notice: Do NOT attempt to separate the metal couplings. Replace both cable pieces if the metal couplings are separated. Both of the cable sections will be damaged if the two metal couplings are disconnected. 4. Push up to the adjustment position to release the adjuster until the cable housings separate. 5. Depress the adjuster clip once. This mobilizes the adjuster housing toward the transaxle end fitting. 6. Line up the end fittings so they slide together until you feel the parts cam together and lock. 7. Depress the adjuster clip completely. This locks the cable into its adjusted service position. 8. Pull the conduit in the opposite direction to assure full system adjustment of the shift cable. Important: The horseshoe clip with the tab is flush when fully engaged. 9. Ensure the conduit is fully engaged. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4762 10. The horseshoe clip with the tab is not flush when not fully engaged. 11. Install the shift cable retainer and the wiring harness clip or wiring harness strap. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4763 Shift Cable: Service and Repair Automatic Transmission Range Selector Cable Replacement Removal Procedure Caution: The automatic transaxle range selector cable is made out of two cable sections. After initial connection never separate the two metal couplings from one another. Integrity of the connection of the two metal couplings will be lost if separation of the two metal couplings occurs. When servicing the transaxle remove the cable at the automatic transaxle range selector lever and at the automatic transaxle range selector cable bracket. If either section of the cable needs to be replaced, replace both of the cable sections. Loss of connection integrity of the two metal couplings can cause loss of transaxle shift control which could result in personal injury. 1. Remove the air cleaner intake duct. 2. Remove the automatic transaxle range selector cable from the wiring harness clip or strap. 3. Remove the automatic transaxle range selector cable retainer. 4. Remove the automatic transaxle range selector cable from the automatic transaxle range selector lever. 5. Remove the automatic transaxle range selector cable from the automatic transaxle range selector cable bracket. 6. If equipped with a floor console, remove the front floor console. 7. Pull the carpet back to expose the automatic transaxle range selector cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4764 8. Remove the automatic transaxle range selector cable retainer from the console shift control. 9. Remove the automatic transaxle range selector cable from the console shift control. 10. Remove the automatic transaxle range selector cable from the console shift control bracket. 11. If equipped with a steering column shift control, remove the left knee bolster bracket. 12. Remove the automatic transmission range selector cable from the shift control lever. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4765 13. Install a piece of mechanics wile to the end of the automatic transmission range selector cable. 14. Remove the automatic transmission range selector cable through the hole in the cowl. Installation Procedure Caution: The automatic transaxle range selector cable is made out of two cable sections. After initial connection never separate the two metal couplings from one another. Integrity of the connection of the two metal couplings will be lost if separation of the two metal couplings occurs. When servicing the transaxle remove the cable at the automatic transaxle range selector lever and at the automatic transaxle range selector cable bracket. If either section of the cable needs to be replaced, replace both of the cable sections. Loss of connection integrity of the two metal couplings can cause loss of transaxle shift control which could result in personal injury. 1. Install the automatic transmission range selector cable through the hole in the cowl. 2. Remove the mechanics wire from the end of the automatic transmission range selector cable. 3. If equipped with a steering column shift control, install the automatic transmission range selector cable to the shift control lever. 4. Install the left knee bolster bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4766 5. If equipped with a floor console shift control, install the automatic transaxle range selector cable to the console shift control bracket. 6. Install the automatic transaxle range selector cable to the console shift control. 7. Install the automatic transaxle range selector cable retainer to the console shift control. 8. Install the carpet into position. 9. Install the Front Floor Console. 10. Properly route and position the automatic transmission range selector cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4767 11. Install the automatic transaxle range selector cable to the automatic transaxle range selector cable bracket. 12. Install the automatic transaxle range selector cable to the automatic transaxle range selector lever. 13. Install the automatic transaxle range selector cable retainer. 14. Place the transaxle in the Neutral position. 15. Place the shift control in the Neutral position. 16. Connect each cable section to the following before connecting the two cable sections. ^ Insert the metal end fitting of the shift control cable into the transaxle cable end. ^ Use the molded end fittings to push the metal end fitting of the shift control cable and the transaxle cable end together until the metal post snaps into place. 17. Depress the adjuster clip once. This mobilizes the adjuster housing toward the transaxle end fitting. 18. Line up the end fittings so they slide together until you feel the parts cam together and lock. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4768 19. Depress the adjuster clip completely. This locks the cable into its adjusted service position. 20. Pull the conduit in the opposite direction to assure full system adjustment of the shift cable. Important: The horseshoe clip with the tab is flush when fully engaged. 21. Ensure the conduit is fully engaged. 22. The horseshoe clip with the tab is not flush when not fully engaged. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Adjustments > Page 4769 23. Install the automatic transaxle range selector cable to the wiring harness clip or strap. 24. Adjust the automatic transaxle range selector cable. 25. Install the air cleaner intake duct. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: Customer Interest A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 4778 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > Customer Interest for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 4779 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear Sun Gear: All Technical Service Bulletins A/T - 4L60/65E, No Reverse/2nd or 4th Gear TECHNICAL Bulletin No.: 00-07-30-022D Date: June 10, 2008 Subject: No Reverse, Second Gear or Fourth Gear (Replace Reaction Sun Shell with More Robust Heat Treated Parts) Models: 1993 - 2005 GM Passenger Cars and Light Duty Trucks 2003 - 2005 HUMMER H2 with 4L60/65-E Automatic Transmission (RPOs M30 or M32) Supercede: This bulletin is being revised to add 2005 model year to the parts information. Please discard Corporate Bulletin Number 00-07-30-022C (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a no reverse, no second or no fourth gear condition. First and third gears will operate properly. Cause The reaction sun gear (673) may not hold inside the reaction sun shell (670). Correction Important: There are FOUR distinct groups of vehicles and repair procedures involved. Vehicles built in the 2001 model year and prior that make use of a reaction shaft to shell thrust washer: ^ The sun shell can be identified by four square holes used to retain the thrust washer. Use reaction sun shell P/N 24228345, reaction carrier to shell thrust washer (699B) P/N 8642202 and reaction sun gear shell thrust washer (674) P/N 8642331er (674) P/N 8642331along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and prior that have had previous service to the reaction sun shell: It is possible that some 2001 and prior model year vehicles have had previous service to the reaction sun shell. At the time of service, these vehicles may have been updated with a Reaction Sun Shell Kit (Refer to Service Bulletin 020730003) without four square holes to retain the thrust washer. If it is found in a 2001 model year and prior vehicles that the reaction sun shell DOES NOT have four square holes to retain the thrust washer, these vehicles must be serviced with P/Ns 24229825 (674), 24217328 and 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built in the 2001 model year and later that make use of a reaction shaft to shell thrust bearing: The sun shell can be identified by no holes to retain the thrust washer. Use reaction sun shell, P/N 24229825, reaction carrier shaft to shell thrust bearing (669A), P/N 24217328 and reaction sun gear shell thrust washer (674), P/N 8642331 along with the appropriate seals and washers listed below. ^ Vehicles built from November, 2001 through June, 2002: These vehicles should have the reaction carrier shaft replaced when the sun shell is replaced. Use shell kit P/N 24229853, which contains a sun shell (670), a reaction carrier shaft (666), a reaction carrier shaft to shell thrust bearing (669A) and a reaction sun gear shell thrust washer (674). The appropriate seals and washers listed below should also be used. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Follow the service procedure below for diagnosis and correction of the no reverse, no second, no forth condition. Important: If metallic debris is found on the transmission magnet, the transmission must be completely disassembled and cleaned. Metallic debris is defined as broken parts and pieces of internal transmission components. This should not be confused with typical "normal" fine particles found on all transmission magnets. Failure to properly clean the transmission case and internal components may lead to additional repeat repairs. 1. Remove the transmission oil pan and inspect the magnet in the bottom of the pan for metal debris. Refer to SI Document ID # 825141. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 4785 2. Remove the transmission from the vehicle. Refer to the appropriate SI document. Important: ^ Inspect all the transmission components for damage or wear. Replace all damaged or worn components. The parts shown above should be sufficient to correct this concern. ^ This condition does not normally require replacement of the transmission completely. Components such as clutches, valve body, pump and torque converters will NOT require replacement to correct this condition. Disassemble the transmission and replace the appropriate parts listed below. Refer to the Unit Repair Manual - Repair Instructions. 3. Reinstall the transmission in the vehicle. Refer to appropriate service information. When servicing the transmission as a result of this condition, the transmission oil cooler and lines MUST be flushed. Refer to Corporate Bulletin Number 02-07-30-052. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Gear: > 00-07-30-022D > Jun > 08 > A/T - 4L60/65E, No Reverse/2nd or 4th Gear > Page 4786 Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information Torque Converter: Technical Service Bulletins A/T - Torque Converter Replacement Information INFORMATION Bulletin No.: 01-07-30-010C Date: May 12, 2008 Subject: Automatic Transmission/Transaxle Torque Converter Replacement Models: 2009 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saturn Cars and Light Duty Trucks (Except VTi Equipped Vehicles (RPO M16 and M75) 2009 and Prior Saab 9-7X with ALL Automatic Transmissions and Transaxles Supercede: This bulletin is being revised to add the 2007-2009 model years. Please discard Corporate Bulletin Number 01-07-30-010B (Section 07 - Transmission/Transaxle). The purpose of this bulletin is to help technicians determine when a torque converter should be replaced. Below is a list of general guidelines to follow. The converter should NOT be replaced if the following apply: ^ DTC P0742 - TCC stuck on is set. This code is almost always the result of a controls condition (i.e. stuck TCC solenoid/valve). Experience has shown that this code rarely indicates a mechanical concern within the torque converter. ^ The fluid has an odor or is discolored but no evidence of metal contamination. ^ Fine metal particles (traces of metal flakes/gray color to fluid ) are found in the converter. This is not harmful to the torque converter. ^ The vehicle has been exposed to high mileage. ^ A small amount of wear appears on the hub where the oil pump drive gear mates to the converter (RWD only). A certain amount of such wear is normal for both the hub and oil pump gear. Neither the converter nor the front pump assembly should be replaced. The torque converter should be replaced under any of the following conditions: ^ The vehicle has TCC shudder and/or no TCC apply. First complete all electrical and hydraulic diagnosis and check for proper engine operation. The converter clutch may be damaged. Also the converter bushing and/or internal 0-ring may be damaged. ^ Evidence of damage to the oil pump assembly pump shaft turbine shaft drive sprocket support and bearing or metal chips/debris in the converter. ^ Metal chips/debris are found in the converter or when flushing the cooler and the cooler lines. ^ External leaks in the hub weld area lug weld or closure weld. ^ Converter pilot is broken damaged or fits poorly into the crankshaft. ^ The converter hub is scored or damaged. ^ The transmission oil is contaminated with engine coolant engine oil or water. ^ If excessive end play is found after measuring the converter for proper end play (refer to Service Manual). ^ If metal chips/debris are found in the fluid filter or on the magnet and no internal parts in the unit are worn or damaged. This indicates that the material came from the converter. ^ The converter has an unbalanced condition that results in a vibration that cannot be corrected by following Converter Vibration Procedures. ^ Blue converter or dark circular ring between lugs. This condition will also require a complete cleaning of the cooler and a check for adequate flow Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T - Torque Converter Replacement Information > Page 4791 through the cooler. ^ Converter bearing noise determined by noise from the bell housing area in Drive or Reverse at idle. The noise is gone in Neutral and Park. ^ If silicon from the viscous clutch is found in the lower pan (4T80-E ONLY). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 4792 Torque Converter: Service and Repair Flywheel to Torque Converter Bolt Replacement Tools Required ^ J 37096 Flywheel Holder Removal Procedure 1. Raise and support the vehicle. 2. Remove the torque converter cover bolts. 3. Remove the torque converter covers. 4. Install the J 37096 in order to gain access to the torque converter bolts and to prevent the flywheel from turning. 5. Remove the flywheel to torque converter bolts. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 4793 1. Install the J 37096 in order to gain access to the torque converter bolts and to prevent the flywheel from fuming. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the flywheel to torque converter bolts. Tighten the bolts to 63 Nm (47 ft. lbs.). 3. Install the torque converter covers. 4. Install the torque converter cover bolts. Tighten the bolts to 10 Nm (89 inch lbs.) 5. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting Torque Converter Check Valve: Technical Service Bulletins A/T - Revised Converter Check Valve/Cooler Line Fitting INFORMATION Bulletin No.: 04-07-30-017B Date: November 25, 2008 Subject: Information on 4T65-E MN7, M15, M76, MN3 Automatic Transmission Case, Cooler Fitting and Torque Converter Drain Back Check Ball Change Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks with one of the HYDRA-MATIC(R) Automatic Transmissions shown above. Supercede: This bulletin is being revised to update the Parts Information. Please discard Corporate Bulletin Number 04-07-30-017A (Section 07 - Transmission/Transaxle). Effective with Julian date 4019 (January 19, 2004), the 4T65E transaxle cases and cooler fittings have changed and are not interchangeable with past models. The technician may find that when replacing the inlet or outlet transmission cooler lines, the new lines cannot be connected to the transmission. A change to the transmission cooler line fittings was implemented in production on February 1, 2004. The cooler line fittings were changed to a design with a longer lead in pilot (1). The cooler line fittings with the longer lead in pilot will not fit on models built before February 1, 2004. The longer lead in pilot fittings (1) (9/16-18 UNF) have replaced the shorter lead in pilot fittings (2) (3/8-18 NPSF w/check ball & 1/4-18 NPSF). If the transmission cooler lines will not connect, then replace them with the following cooler line fittings as appropriate with the older, shorter lead in pilot design: ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Inlet Hose, P/N 20793004. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Inlet Hose, second design P/N 15264588. ^ For vehicles built prior to February 1, 2004, use Transmission Fluid Cooler Outlet Hose, P/N 20793005. ^ For vehicles built after February 1, 2004, use Transmission Fluid Cooler Outlet Hose, second design P/N 15264589. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Check Valve > Component Information > Technical Service Bulletins > A/T - Revised Converter Check Valve/Cooler Line Fitting > Page 4798 The torque specification has changed for the fittings to case. The torque has changed from 38 Nm (28 lb ft) to 32 Nm (23 lb ft). Tighten Tighten the new cooler fittings to 32 Nm (23 lb ft). The converter drain back check ball (420C) has been removed from the cooler line fitting and is now located in the channel plate. If you get a concern of no movement in the morning or after sitting for several hours, the cooler check ball should be inspected. The best way to determine where the check ball is located is to look at the cooler line fittings. The old fittings are different sizes (3/8-18 NPSF & 1/4-18 NPSF) and would contain the cooler check ball. The new fittings are the same size as each other (9/16-18 UNF) and do not have a cooler check ball. Parts Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 4802 Torque Converter Clutch Pulse Width Modulated Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch (TCC) Solenoid Torque Converter Clutch (TCC) Solenoid Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Remove the TCC solenoid retaining clip (314) 4. Remove the TCC solenoid (315). Installation Procedure 1. install the TCC solenoid (315). 2. Install the TCC solenoid retaining clip (314). 3. Connect the TCC solenoid electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 4805 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect and reposition the electrical connectors from the following: ^ If equipped internal mode switch ^ 2 - 3 Shift solenoid valve assembly (315B) ^ Automatic transaxle fluid pressure manual valve position switch assembly (395) Important: Do NOT remove the bolt (205) that holds the oil pump together. 3. Remove the oil pump bolts (206, 207). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 4806 4. Remove the oil pump (200) from the valve body (300). 5. Disconnect the Torque Converter Clutch Pulse Width Modulation (TCC PWM) solenoid electrical connector. 6. Remove the TCC PWM solenoid retaining clip (314F). 7. Remove the TCC PWM solenoid (334). Installation Procedure 1. Install the TCC PWM solenoid (334). 2. Install the TCC PWM solenoid retaining clip (314F). 3. Connect the TCC PWM solenoid electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 4807 4. Install the oil pump (200) to the valve body (300). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pump bolts (206, 207). Tighten ^ Tighten the bolts (207) to 12 Nm (106 inch lbs.). ^ Tighten the bolts (206) to 16 Nm (12 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 4808 6. Reposition and connect the electrical connectors to the following: ^ Automatic transaxle fluid pressure manual valve position switch assembly (395) ^ 2 - 3 Shift solenoid valve assembly (315B) ^ If equipped internal mode switch 7. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter Cover > Component Information > Service and Repair Torque Converter Cover: Service and Repair Torque Converter Cover Replacement Removal Procedure 1. Raise and support the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Remove the torque converter cover bolts 3. Remove the torque converter covers. Installation Procedure 1. install the torque converter covers. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the torque converter cover bolts Tighten the bolts to 10 Nm (89 inch lbs.). 3. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush Transmission Cooler: Technical Service Bulletins A/T - Fluid Oil Cooler Flush INFORMATION Bulletin No.: 02-07-30-052G Date: March 02, 2011 Subject: Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow(R) Models: 2011 and Prior Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 with Automatic Transmission/Transaxle including Allison(R) Transmissions Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 02-07-30-052F (Section 07 - Transmission/Transaxle). Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. The J 45096 transmission oil cooling system flush and flow test tool replaces current tool J 35944-A. J 45096 is a self-contained unit utilizing a 12-volt flow meter, shop air supply and DEXRON(R) VI automatic transmission fluid (ATF). In the flush mode, transmission fluid is cycled through the transmission oil cooling system. High-pressure air is automatically injected into the fluid stream adding agitation to the ATF oil to enhance the removal of contaminated ATF oil and debris. In the flow mode, an electronic flow meter is used to measure the flow capability of the ATF oil cooling system. A digital display indicates the ATF oil flow rate in gallons per minute (GPM) along with the amount of ATF oil in the supply vessel, supply vessel ATF oil temperature, machine cycles and the operating mode. The supply oil vessel has 30 L (32 qt) capacity and the waste oil vessel has 32 L (34 qt) capacity. The waste oil vessel is constructed of a translucent composite material that allows the user to easily identify the oil level. The waste oil vessel can accommodate vacuum evacuation and gravity draining. In the code mode, a random, encrypted code is generated that can be used for verification of flow test results. Current essential cooler line adapters are used to connect the J 45096 to the automatic transmission oil cooler lines that allows J 45096 to adapt to General Motors passenger cars and light duty trucks, current and past models (except the Pontiac Vibe, Wave and Chevrolet Aveo). The tool may be adapted for use on the Pontiac Vibe, Wave and Chevrolet Aveo by dealership personnel with a barbed hose connector and rubber hose obtained locally. The Vibe's/Wave's/Aveo's transmission has a transmission oil requirement which is slightly different than DEXRON(R) VI ATF. However, flushing the cooler with DEXRON(R) VI automatic transmission fluid is an acceptable service procedure. Very little fluid remains in the cooler after the flush procedure and the residual DEXRON(R) VI ATF in the cooler is compatible with the Vibe's/Wave's/Aveo's transmission fluid. Notice Insufficient oil flow through the ATF oil cooling system will cause premature transmission failure. The required minimum ATF oil flow rate reading is directly related to the supply oil temperature. Refer to the flow rate reference chart for the oil flow rate specification based on the temperature of the ATF in the supply vessel. Helpful Hints for Maintaining the Temperature at or above 18°C (65°F) Important - The temperature of the supply vessel oil must be 18°C (65°F) or greater for J 45096 to operate. It is recommended to store the J 45096 in an area of the dealership where the room temperature remains at or above 18°C (65°F) when not in use. - Do not attempt to increase the fluid temperature in the Transflow(R) machine with an engine oil dipstick, or any other immersion type heater. The Transflow(R) machine has a check valve in the supply reservoir. Inserting a heater will damage the check valve and the subsequent repair expense would be the dealer's responsibility. - A heater blanket, P/N J-45096-10, is available for the Transflow(R) transmission cooling system flushing tool. This heater fastens around the Transflow(R) internal supply vessel and runs on 110 volts AC. The heater will warm the ATF in the supply vessel to at least 18°C (65° F) and has a thermostat to hold a constant temperature. Store the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine in a room where the temperature is maintained at or above 18°C (65°F). Keep the ATF level in the reservoir low when the Transmission Cooling System Service Tool, J 45096, Transflow(R), is not in use. Store several gallons of oil in an area where the temperature is maintained at or above 18°C (65°F). Fill the reservoir of the J 45096 as needed before using the machine on Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 4816 each repair. With the ATF in a tightly sealed container, place the container in a tub of hot water for a period of time. Then pour the ATF into the reservoir. This method works best with a low fluid level in the reservoir. Place the Transflow(R) machine in the direct sunlight with the cabinet door open to expose the reservoir to the rays of the warm sun. Flush / Flow Test Procedure Important All labor operations that include removal of the transmission from the vehicle and require the transmission oil pan or transmission side cover to be removed include labor time to flush the transmission oil cooler system. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate procedure. Important The J 45096 can be used to flush the transmission oil cooler system on an Allison equipped vehicle, but the flow meter should not be utilized. Refer to SI for Automatic Transmission Oil Cooler Flushing and Flow Test J 45096 for the appropriate flow check procedure. Machine Displays After completion of the flush and flow test, the following information is to be recorded on the repair order. This information is displayed on the Transmission Cooling System Service Tool, J 45096, Transflow(R) machine when the dial is in the code position. - Tested flow rate (displayed in Gallons Per Minute (GPM) - Temperature (displayed is degrees Fahrenheit) - Cycle number (a number) - Seven digit Alpha/Numeric flow code (i.e. A10DFB2) Warranty Information Important All labor operations that include removal of the transmission from the vehicle include labor time to flush the transmission oil cooler system. Performing a transmission oil cooling system flush and flow test will use between 4.7-7.5 L (5-8 qts) of DEXRON(R)VI transmission fluid. The amount Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 4817 of transmission fluid (ATF), (DEXRON(R)VI) (fluid) that is to be charged for the flush portion of the repair should not exceed the allowable charge for 7.5 L (2 gal) of fluid. This expense should be shown in the Parts Section of the warranty claim document. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. The Seven digit Alpha/Numeric flow code, i.e. A10DFB2, "MUST" be written on the job card, entered in the warranty claim labor operation Flush Code additional field (when available) and placed in the comments section of the warranty claim. Any repair that requires the technician to contact the Product Quality Center (PQC) must also include the seven digit flow code. The agent will request the seven digit flow code and add the information to the PQC case prior to providing authorization for the warranty claim. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 4818 Transmission Cooler: Technical Service Bulletins A/T - Water Or Coolant Contamination Information INFORMATION Bulletin No.: 08-07-30-035B Date: November 01, 2010 Subject: Information on Water or Ethylene Glycol in Transmission Fluid Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks with Automatic Transmission Supercede: This bulletin is being revised to update model years. Please discard Corporate Bulletin Number 08-07-30-035A (Section 07 - Transmission/Transaxle). Water or ethylene glycol in automatic transmission fluid (ATF) is harmful to internal transmission components and will have a negative effect on reliability and durability of these parts. Water or ethylene glycol in ATF will also change the friction of the clutches, frequently resulting in shudder during engagement or gear changes, especially during torque converter clutch engagement. Indications of water in the ATF may include: - ATF blowing out of the transmission vent tube. - ATF may appear cloudy or, in cases of extreme contamination, have the appearance of a strawberry milkshake. - Visible water in the oil pan. - A milky white substance inside the pan area. - Spacer plate gaskets that appear to be glued to the valve body face or case. - Spacer plate gaskets that appear to be swollen or wrinkled in areas where they are not compressed. - Rust on internal transmission iron/steel components. If water in the ATF has been found and the source of the water entry has not been identified, or if a leaking in-radiator transmission oil cooler is suspected (with no evidence of cross-contamination in the coolant recovery reservoir), a simple and quick test kit is available that detects the presence of ethylene glycol in ATF. The "Gly-Tek" test kit, available from the Nelco Company, should be obtained and the ATF tested to make an accurate decision on the need for radiator replacement. This can help to prevent customer comebacks if the in-radiator transmission oil cooler is leaking and reduce repair expenses by avoiding radiator replacement if the cooler is not leaking. These test kits can be obtained from: Nelco Company Test kits can be ordered by phone or through the website listed above. Orders are shipped standard delivery time but can be shipped on a next day delivery basis for an extra charge. One test kit will complete 10 individual fluid sample tests. For vehicles repaired under warranty, the cost of the complete test kit plus shipping charges should be divided by 10 and submitted on the warranty claim as a net item. The transmission should be repaired or replaced based on the normal cost comparison procedure. Important If water or coolant is found in the transmission, the following components MUST be replaced. - Replace all of the rubber-type seals. - Replace all of the composition-faced clutch plates and/or bands. - Replace all of the nylon parts. - Replace the torque converter. - Thoroughly clean and rebuild the transmission, using new gaskets and oil filter. Important The following steps must be completed when repairing or replacing. Flush and flow check the transmission oil cooler using J 45096. Refer to Corporate Bulletin Number 02-07-30-052F- Automatic Transmission Oil Cooler Flush and Flow Test Essential Tool J 45096 TransFlow. - Thoroughly inspect the engine cooling system and hoses and clean/repair as necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 4819 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 4820 Transmission Cooler: Technical Service Bulletins A/T - Oil Cooler Flushing Frequently Asked Questions File In Section: 07 - Transmission/Transaxle Bulletin No.: 03-07-30-027 Date: June, 2003 INFORMATION Subject: Most Frequently Asked Questions and Answers for J 45096 TransFlow Transmission Oil Cooling System Flushing Machine Models: 2004 and Prior Passenger Cars and Light Duty Trucks with Automatic Transmission/Transaxle 2004 and Prior HUMMER H2 This bulletin is issued to help answer the most frequently asked questions and concerns about essential tool J 45096. Q: Why doesn't the machine work below 18°C (65°F)? A: The flow characteristics of ATF at temperatures below 18°C (65°F) does not provide accurate flow test results with the electronics used in the J 45096. Q: Why didn't the unit come with a tank heater? A: The vast majority of dealerships do not require a heater to keep the ATF above 18°C (65°F). As a result, the heater was deleted as a cost-savings measure. A tank heater, J 45096-10, is currently available from Kent-Moore if your dealership requires it. Refer to Corporate Bulletin Number 03-07-30-002A for suggestions on warming the ATF without using a heater blanket. Q: Why does the machine fail new oil coolers? A: Several reasons have been found. The most likely reason is the air pressure at the air hose connected to the J 45096 is less than 586 kPa (85 psi). Other reasons include a twisted hose inside the J 45096 at the bulkhead as a result of the nut turning when the waste or supply hose was installed, the internal pressure regulator was improperly set at the factory or a problem with the cooler lines on the vehicle. Perform the J 45096 self-test as described on pages 9 and 10 of the Operation Manual. If a problem is still detected, refer to Troubleshooting on page 19 of the Operation Manual. If a problem still persists, contact Kent-Moore Customer Service at 1-800-345-2233. Q: What is the difference between steel and aluminum oil coolers? A: The aluminum oil cooler tube is slightly thinner in construction than the steel oil cooler tube, which affects the oil flow rate. The fitting that is protruding out of the radiator tank easily identifies the aluminum oil cooler. Refer to the Quick Reference card provided with the J 45096 in order to identify the proper flow rate for the aluminum oil cooler. Q: Why can't I use TransFlow for Allison transmission cooling Systems? A: Validation of TransFlow is currently under development for light duty trucks equipped with the Allison automatic transmission. TransFlow is based on the existing MINIMUM flow rate specification through the transmission oil cooling system. The Allison transmission oil cooling system only has MAXIMUM oil flow rates specified and J 45096 does not have the capability to test the transmission oil cooling system at the maximum oil flow rate specification. Q: Why doesn't GM publish a specification for auxiliary transmission oil coolers? A: The auxiliary oil cooler used with GM vehicles does not contain an internal turbulator plate like the radiator tank oil cooler does. Therefore, there is no internal restriction that would affect the flow rate through the oil cooling system so a specification for auxiliary oil cooler is not required. Keep in mind, kinks and damage to the auxiliary cooler and lines can affect the flow rate through the system. Q: Why did GM drop the labor time for transmission repairs? A: The labor for flushing and flow testing the transmission oil cooling system is included with the R&R; labor of the "K" labor operations that require transmission removal. The time required to use the J 45096 to perform the flush and flow test is much less than that of the J 35944-A. The warranty labor savings allowed GM to provide the J 45096 at no cost to dealerships. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > A/T - Fluid Oil Cooler Flush > Page 4821 Q: Why didn't the machine come with the adapters to hook up to the car? A: The J 45096 was designed to use the previously released essential cooler line adapters for the J 35944-A. All adapters are listed on page 17 of the Operation Manual and can be ordered from Kent-Moore at 1-800-345-2233. Q: How do I connect the J 45096 to a Catera, Prizm or a Vibe? A: These vehicles, along with many other models, only require barbed fittings to connect to the rubber cooler hose. These fittings are commercially available and already found in many shops. Q: Why didn't I receive an Operation Manual with the machine? A: The Operation Manual was packaged in the upper portion of the shipping carton. If the shipping carton was lifted off the base without opening the top of the carton, the Operation Manual could have been discarded with the carton. Replacement Operation Manual packages can be obtained from Kent-Moore Customer Service at 1-800-345-2233. Q: Why can't I re-use the transmission fluid I use for flushing? A: The very fine metal and clutch material debris from the transmission failure in the ATF causes failures with the hall effect speed sensors that are used to measure the flow rate. To avoid costly repairs, expensive filters, regular maintenance and problems caused by a partially restricted filter, the filter was not included. Q: What do I do if I need service on my machine? A: Call Kent-Moore Customer Service at 1-800-345-2233. The J 45096 has a one-year warranty. Q: Can I flush and flow engine oil coolers? A: The engine oil cooler flow rates, the appropriate adapters and an acceptable procedure are currently under development. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission Oil Cooler Fitting Replacement Transmission Cooler: Service and Repair Automatic Transmission Oil Cooler Fitting Replacement Automatic Transmission Oil Cooler Fitting Replacement Removal Procedure Notice: Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to prevent damage or wear which may cause fluid loss. 1. Raise and support the vehicle. 2. Position a drain pan under the vehicle. 3. Remove the transaxle oil cooler hoses from the transaxle oil cooler fittings. 4. Remove the transaxle oil cooler fittings (28, 29) from the transaxle. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. Important: The correct thread engagement is critical. Crossthreaded fittings can achieve proper tightness and still leak. 1. Install the transaxle oil cooler fittings (28, 29) to the transaxle. Tighten the fittings to 38 Nm (28 ft. lbs.). 2. Install the transaxle oil cooler hoses to the transaxle oil cooler fittings. 3. Lower the vehicle. Notice: Refer to Transmission Overfill Notice. 4. Adjust the fluid level. 5. Inspect for fluid leaks. 6. Remove the drain pan from under the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission Oil Cooler Fitting Replacement > Page 4824 Transmission Cooler: Service and Repair Auxiliary Automatic Transmission Oil Cooler Replacement Auxiliary Automatic Transmission (AT) Oil Cooler Replacement Removal Procedure Notice: Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to prevent damage or wear which may cause timid loss 1. Remove the upper radiator air baffle. 2. Remove the auxiliary transaxle oil cooler bolt from the upper radiator support. 3. Raise and support the vehicle. 4. Remove the auxiliary transaxle oil cooler bolts from the lower radiator support. 5. Remove the inlet and outlet auxiliary transmission oil cooler lines from the support clips. 6. Lower the auxiliary transaxle oil cooler below the front bumper. 7. Remove the inlet and outlet auxiliary transaxle oil cooler hoses from the auxiliary transaxle oil cooler. 8. Remove the auxiliary transaxle oil cooler Installation Procedure 1. Install the inlet and outlet auxiliary transaxle oil cooler hoses to the auxiliary transaxle oil cooler. 2. Install the auxiliary transaxle oil Cooler, to the vehicle. 3. Install the inlet and outlet auxiliary transmission oil cooler lines to the support clips Notice: Refer to Fastener Notice in Service Precautions. 4. Install the auxiliary transaxle oil cooler bolts to the lower radiator support. Tighten the bolts to 10 Nm (97 inch lbs.) 5. Lower the vehicle. 6. Install the auxiliary transaxle oil cooler bolt to the upper radiator support. Tighten the bolt to 25 Nm (18 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission Oil Cooler Fitting Replacement > Page 4825 7. Install the upper radiator air baffle. 8. Adjust the fluid level. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Service and Repair > Automatic Transmission Oil Cooler Fitting Replacement > Page 4826 Transmission Cooler: Service and Repair Auxiliary Automatic Transmission Oil Cooler Hose Replacement Auxiliary Automatic Transmission (AT) Oil Cooler Hose Replacement Removal Procedure Notice: Allow sufficient clearance around the transaxle oil cooler pipes and around the hoses to prevent damage or wear which may cause fluid loss. 1. Raise and support the vehicle. 2. Remove the inlet and outlet auxiliary transmission oil cooler lines from the support clip (1) and (3). 3. Remove the inlet auxiliary transmission oil cooler line from the transmission. 4. Remove the outlet auxiliary transmission oil cooler line from the lower radiator side tank. 5. Remove the inlet and outlet auxiliary transmission oil cooler lines from the auxiliary transmission oil cooler. Installation Procedure 1. Install the inlet and outlet auxiliary transmission oil cooler lines to the auxiliary transmission oil cooler. 2. Install the inlet and outlet auxiliary transmission oil cooler lines to the support clip (1) and (3). 3. Install the outlet auxiliary transmission oil cooler line to the lower radiator side tank. 4. Install the inlet auxiliary transmission oil cooler line to the transmission. 5. Lower the vehicle. Notice: Do NOT overfill the transaxle. The overfilling of the transaxle causes foaming, loss of fluid, shift complaints, and possible damage to the transaxle. 6. Adjust the fluid level. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Inspection Transmission Mount: Service and Repair Transmission Mount Inspection Transmission Mount Inspection Notice: In order to avoid oil pan damage and possible engine failure, insert a block of wood that spans the width of the oil pan bottom between the oil pan and the jack support. 1. Raise and support the vehicle. Important: Before replacing any transmission/transaxle mount due to suspected fluid loss, verify that the source of the fluid is the transmission/transaxle mount, not the engine transmission/transaxle or accessories. 2. Raise the transmission/transaxle in order to remove the weight from the transmission/transaxle mount and create slight tension in the rubber. 3. Observe the transmission/transaxle mount while raising the transmission/transaxle. Replace the transmission/transaxle mount if the transmission/transaxle mount exhibits any of the following conditions: ^ The hard rubber surface is covered with heat check cracks. ^ The rubber is separated from the metal plate of the transmission/transaxle mount ^ The rubber is split through the center of the transmission/transaxle mount. ^ If the transaxle needs replaced. 4. If there is movement between the metal plate of the transmission/transaxle mount and its attaching points, lower the transmission/transaxle on the transmission/transaxle mount. Tighten the bolts or nuts attaching the transmission/transaxle mount to the frame or transmission/transaxle mount bracket. 5. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Inspection > Page 4831 Transmission Mount: Service and Repair Automatic Transmission Mount Replacement Automatic Transmission Mount Replacement Removal Procedure 1. Raise and support tire vehicle. 2. Remove the left tire and wheel, assembly. 3. Remove left inner splash shield. 4. Position a transmission jack under the transaxle. 5. Remove the transaxle mount upper nuts from the transaxle bracket. 6. Carefully raise the transaxle assembly. 7. Remove the transaxle mount lower nuts from the frame. 8. Remove the transaxle mount from the frame. Installation Procedure 1. Position the transaxle mount to the frame. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Inspection > Page 4832 Notice: Refer to Fastener Notice in Service Precations. 2. Install the transaxle mount lower nuts to the frame. Tighten the transaxle mount lower nuts to 63 Nm (46 ft. lbs.). 3. Lower the transaxle so the transaxle mount studs install into the transaxle bracket. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the transaxle mount upper nuts to the transaxle mount. Tighten the transaxle mount upper nuts to 47 Nm (35 ft. lbs.). 5. Remove the transmission jack from the transaxle. 6. Install left inner splash shield. 7. Install the left wheel and tire assembly. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Inspection > Page 4833 Transmission Mount: Service and Repair Automatic Transmission Brace Replacement Automatic Transmission Brace Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the right front tire and wheel assembly. 3. Remove the transaxle brace bolts. 4. Remove the transaxle brace Installation Procedure 1. Install the transaxle brace. Notice: Refer to Fastener Notice in Service Precautions 2. Install the transaxle grace bolts to the transaxle. Tighten the transaxle brace bolts to the transaxle to 43 Nm (32 ft. lbs.) 3. Install the transaxle brace bolts to the engine. Tighten the transaxle brace bolts to the engine to 63 Nm (46 ft. lbs.) 4. install the right front tire and wheel assembly. 5. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Inspection > Page 4834 Transmission Mount: Service and Repair Automatic Transmission Mount Bracket Replacement Automatic Transmission Mount Bracket Replacement Removal Procedure 1. Raise and support the vehicle. 2. Remove the left front tire and wheel assembly. 3. Remove the left engine splash shield. 4. Support the transaxle 5. Remove the transaxle bracket to transaxle mount upper nuts. 6. Remove the bolts which secure the transaxle bracket to the transaxle. 7. Remove the transaxle bracket. Installation Procedure 1. Position the transaxle bracket to the transaxle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mount, A/T > Component Information > Service and Repair > Transmission Mount Inspection > Page 4835 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the transaxle bracket bolts. Tighten the bracket bolts to 95 Nm (70 ft. lbs.). 3. Remove the support from the transaxle. 4. Install the upper nuts which secure the transaxle bracket to the transaxle mount. Tighten the upper nuts to 47 Nm (35 ft. lbs.). 5. Install the left engine splash shield. 6. Install the left front tire and wheel. 7. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure Test Port, A/T > Component Information > Service and Repair Transmission Pressure Test Port: Service and Repair Oil Pressure Test Plug Replacement Removal Procedure 1. Remove the air cleaner intake duct. 2. Remove the line pressure pipe plug (38). Installation Procedure 1. Apply GM P/N 12345382 (Canadian P/N 10953489) or equivalent to the line pressure pipe plug. Notice: Refer to Fastener Notice in Service precautions. 2. Install the line pressure pipe plug (38). Tighten the plug to 12 Nm (106 inch lbs.). 3. Install the air cleaner intake duct. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4842 Input Speed Sensor Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4843 Transmission Speed Sensor: Service and Repair Input Speed Sensor Replacement Removal Procedure 1. Remove the case side cover 2. Disconnect the input speed sensor electrical connector. 3. Remove the input speed sensor retaining clip (441). 4. Remove the input speed sensor (440). 5. Inspect the input speed sensor (440) for the following conditions: ^ Damaged or missing magnet ^ Damaged housing ^ Bent or missing electrical terminals ^ Damaged speed sensor clip (441) Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed Sensor, A/T > Component Information > Locations > Page 4844 1. Install the input speed sensor (440). 2. Install the input speed sensor retaining clip (441). 3. Connect the input speed sensor electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 4848 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 4849 Transmission Fluid Temperature Sensor Connector Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement Transmission Temperature Sensor/Switch: Service and Repair Thermo Element Replacement Thermo Element Replacement Tools Required ^ J 34094-A Thermo Element Height Gage Removal Procedure 1. Raise and support the vehicle. 2. Remove the oil pan. 3. Remove the thermo element pins (120, 123) and the washers. 4. Remove the thermo element (121) and the thermo element plate (122). Installation Procedure 1. Use the J 34094-A to set the middle thermo pin (123). 2. Install the new thermo element plate (122). 3. Install the pin (120) and the washer. 4. Use the J 34094-A to set the height of the pin and the washer furthest from the accumulator. 5. Use the J 34094-A to set the height of the second pin (120) and the washer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement > Page 4852 6. Install the thermo element (121) between the two pins (120). The V in the thermo element (121) must contact the thermo element plate (122). 7. Install the oil pan. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement > Page 4853 Transmission Temperature Sensor/Switch: Service and Repair Fluid Temperature Sensor Replacement Fluid Temperature Sensor Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the wiring harness assembly tram the fluid temperature sensor (391) 3. Remove the fluid temperature sensor (391). Installation Procedure 1. install the fluid temperature sensor (391). 2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-002A > Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 Valve Body: Customer Interest A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 INFORMATION Bulletin No.: 08-07-30-002A Date: March 12, 2008 Subject: Information On 4T65-E MN7, M15 and M76 Front Wheel Drive Automatic Transmission Valve Body Reconditioning, DTCs P0741, P0742, P0757, P842, Harsh Shifts or Slips Models Supercede: This bulletin is being updated to include Related Service Document information. Please discard Corporate Bulletin Number 08-07-30-002 (Section 07 - Transmission/Transaxle). The following new service information will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. Related Service Document Corporate Bulletin Number 02-07-30-013 : Incorrect Transmission Shifts, Poor Engine Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck Off/On, DTCs P0757 P0741 P0742 P0730 P0756. Important: If valve body cleaning is not required, DO NOT disassemble bores unless it is necessary to verify movement of valves. Inspection Procedure 1. Using the exploded views below inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. 2. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. 3. If a valve is restricted and cannot be corrected by cleaning the valve and bore replace the valve body. Describe the restricted valve on the repair order. Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body. Otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-002A > Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 4862 Disassembly/Reassembly 1. If a valve is restricted by a metal burr from machining that bore remove the valve and burr then inspect movement in the valve's normal position. If no other debris or restrictions are found reassemble the valve body and install in the transmission. 2. If the valve body has been contaminated with debris from another transmission component failure disassemble all bores for complete cleaning of all valve body components. If possible keep individual bore parts separated for ease of reassembly. Use the following illustrations in this bulletin for a positive identification and location of individual parts: ^ Left Side Control Valve Body Assembly ^ Right Side Control Valve Body Assembly ^ Control Valve Body Assembly Chart Valve Springs and Bore Plugs Caution: Use appropriate eye protection when cleaning the valve body to prevent injury. 3. Using GM Brake Clean or equivalent in a safe and clean environment (clean aluminum pan) clean the valve body and dry it with compressed air. 4. Clean individual valve body components with GM Brake Clean or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-002A > Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 4863 Left Side Control Valve Body Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-002A > Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 4864 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-002A > Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 4865 Right Side Control Valve Body Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-002A > Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 4866 1997-2000 M.Y. Only - Right Side Control Valve Body Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-002A > Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 4867 Valve Body Spring and Bore Plug Chart (Metric) Valve Body Spring and Bore Plug Chart (Inch) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 08-07-30-002A > Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 4868 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Valve Body: Customer Interest A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Incorrect Transmission Shifts, Poor Engine Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck Off/On, DTCs P0757, P0741, P0742, P0730, P0756 # 02-07-30-013E - (May 20, 2005) Models: 2001-2005 GM Passenger Cars with 4T65-E Automatic Transmission 2001-2005 Buick Rendezvous 2005 Buick Terraza 2001-2004 Chevrolet Venture 2005 Chevrolet Uplander 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Montana 2005 Saturn Relay with 4T65-F Transmission (RPOs M15, MN3, MN7, M76) This bulletin is being revised to include additional diagnostic information and clarify model usage. Please discard Corporate Bulletin Number 02-07-30-013D (Section 07 -- Transmission/Transaxle). Condition Some owners may comment on any one or more of the following conditions: ^ The SES lamp is illuminated. ^ The transmission slips. ^ The transmission does not shift correctly, is very difficult to get the vehicle to start moving or the engine lacks the power to move the vehicle. ^ Poor engine performance. Cause The most likely cause of the various conditions may be chips or debris: ^ All years--Pressure Reg. Valve (Bore 1) or Torque Signal Valve (Bore 4) stuck ^ On 2001-2002 vehicles, a plugged orifice on the case side of the spacer plate. ^ ON 2003-2005 vehicles, restricted movement of the 2-3 shift valves in the valve body. ^ On 2003-2005 vehicles, restricted movement of the 3-4 shift valves in the valve body. Technician Diagnosis and Correction ^ The technician's road test reveals the vehicle launches in third or fourth gear (high RPM with slow vehicle acceleration). ^ On 2001-2002 vehicles, a DTC P0756 or P0757 may be stored. ^ On 2003-2005 vehicles, a DTC P0730, P0741, P0748 or P0757 may be stored. ^ Refer to the appropriate Service Information (SI) for additional Diagnostic Assistance. ^ With a Tech 2(R) connected to the vehicle, road test the vehicle and perform the following steps: If the above symptoms are present proceed with the following steps. 1. With the valve body removed and on a workbench, carefully push the valve against spring pressure to check if the valve will snap back to the original position. Or for the valves seated in home position, use a small flat-bladed screwdriver and carefully pry the valve off its seat, quickly remove the screwdriver allowing the valve to return to its seat. If the valve does not snap back unencumbered, then the valve will need to be removed from the valve body. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 4873 2. Once the valve is removed, inspect for any scratching or scoring. 3. If any scratching or scoring is found, then the fingernail test will need to be performed. Important: It has been found that in most cases that the scratches are not severe enough to catch your fingernail. 4. Using your fingernail, move over any scratches to see if your nail will catch on the scratch or score. - If your nail catches in the scratches, the valve will need to be replaced. - If your nail does not catch in the scratches, continue with the next step. 6. Important: Clean the valve body with the machined side down so debris may escape. 7. Clean the valve and bore using brake cleaner. 8. Blow off with shop air. 9. To verify free movement of the valve, dip the valve into clean ATF and install the valve back into the appropriate bore. The valve should move freely. If the valve moves freely, in most cases the valve body will function properly when reinstalled. 10. Reassemble and retest Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 4874 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Valve Body: Customer Interest A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4879 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4880 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-002A > Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 Valve Body: All Technical Service Bulletins A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 INFORMATION Bulletin No.: 08-07-30-002A Date: March 12, 2008 Subject: Information On 4T65-E MN7, M15 and M76 Front Wheel Drive Automatic Transmission Valve Body Reconditioning, DTCs P0741, P0742, P0757, P842, Harsh Shifts or Slips Models Supercede: This bulletin is being updated to include Related Service Document information. Please discard Corporate Bulletin Number 08-07-30-002 (Section 07 - Transmission/Transaxle). The following new service information will aid technicians in providing easy to follow valve body reconditioning instructions and new illustrations to simplify reassembly of the valve body. Related Service Document Corporate Bulletin Number 02-07-30-013 : Incorrect Transmission Shifts, Poor Engine Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck Off/On, DTCs P0757 P0741 P0742 P0730 P0756. Important: If valve body cleaning is not required, DO NOT disassemble bores unless it is necessary to verify movement of valves. Inspection Procedure 1. Using the exploded views below inspect each bore for freedom of valve(s) movement and evidence of debris. Pay particular attention to those valves related to the customer's concern. 2. Verify movement of the valves in their normal installed position. Valves may become restricted during removal or installation. This is normal due to small tolerances between the valves and bores. 3. If a valve is restricted and cannot be corrected by cleaning the valve and bore replace the valve body. Describe the restricted valve on the repair order. Notice: Be sure all solenoids are installed with the electrical connectors facing the non-machined (cast) side of the valve body. Otherwise the solenoids will bind against the transmission case as the valve body bolts are tightened and damage may occur. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-002A > Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 4890 Disassembly/Reassembly 1. If a valve is restricted by a metal burr from machining that bore remove the valve and burr then inspect movement in the valve's normal position. If no other debris or restrictions are found reassemble the valve body and install in the transmission. 2. If the valve body has been contaminated with debris from another transmission component failure disassemble all bores for complete cleaning of all valve body components. If possible keep individual bore parts separated for ease of reassembly. Use the following illustrations in this bulletin for a positive identification and location of individual parts: ^ Left Side Control Valve Body Assembly ^ Right Side Control Valve Body Assembly ^ Control Valve Body Assembly Chart Valve Springs and Bore Plugs Caution: Use appropriate eye protection when cleaning the valve body to prevent injury. 3. Using GM Brake Clean or equivalent in a safe and clean environment (clean aluminum pan) clean the valve body and dry it with compressed air. 4. Clean individual valve body components with GM Brake Clean or equivalent. Coat each valve with clean ATF and reassemble in each bore. Check each valve for free movement during assembly of each bore. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-002A > Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 4891 Left Side Control Valve Body Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-002A > Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 4892 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-002A > Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 4893 Right Side Control Valve Body Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-002A > Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 4894 1997-2000 M.Y. Only - Right Side Control Valve Body Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-002A > Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 4895 Valve Body Spring and Bore Plug Chart (Metric) Valve Body Spring and Bore Plug Chart (Inch) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 08-07-30-002A > Mar > 08 > A/T - Harsh Shifts/Slipping/DTCs P0741/P0742/P0757/P842 > Page 4896 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Valve Body: All Technical Service Bulletins A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set Incorrect Transmission Shifts, Poor Engine Performance, Harsh 1-2 Upshifts, Slips 1st and Reverse, Torque Converter Clutch (TCC) Stuck Off/On, DTCs P0757, P0741, P0742, P0730, P0756 # 02-07-30-013E - (May 20, 2005) Models: 2001-2005 GM Passenger Cars with 4T65-E Automatic Transmission 2001-2005 Buick Rendezvous 2005 Buick Terraza 2001-2004 Chevrolet Venture 2005 Chevrolet Uplander 2001-2004 Oldsmobile Silhouette 2001-2005 Pontiac Aztek, Montana 2005 Saturn Relay with 4T65-F Transmission (RPOs M15, MN3, MN7, M76) This bulletin is being revised to include additional diagnostic information and clarify model usage. Please discard Corporate Bulletin Number 02-07-30-013D (Section 07 -- Transmission/Transaxle). Condition Some owners may comment on any one or more of the following conditions: ^ The SES lamp is illuminated. ^ The transmission slips. ^ The transmission does not shift correctly, is very difficult to get the vehicle to start moving or the engine lacks the power to move the vehicle. ^ Poor engine performance. Cause The most likely cause of the various conditions may be chips or debris: ^ All years--Pressure Reg. Valve (Bore 1) or Torque Signal Valve (Bore 4) stuck ^ On 2001-2002 vehicles, a plugged orifice on the case side of the spacer plate. ^ ON 2003-2005 vehicles, restricted movement of the 2-3 shift valves in the valve body. ^ On 2003-2005 vehicles, restricted movement of the 3-4 shift valves in the valve body. Technician Diagnosis and Correction ^ The technician's road test reveals the vehicle launches in third or fourth gear (high RPM with slow vehicle acceleration). ^ On 2001-2002 vehicles, a DTC P0756 or P0757 may be stored. ^ On 2003-2005 vehicles, a DTC P0730, P0741, P0748 or P0757 may be stored. ^ Refer to the appropriate Service Information (SI) for additional Diagnostic Assistance. ^ With a Tech 2(R) connected to the vehicle, road test the vehicle and perform the following steps: If the above symptoms are present proceed with the following steps. 1. With the valve body removed and on a workbench, carefully push the valve against spring pressure to check if the valve will snap back to the original position. Or for the valves seated in home position, use a small flat-bladed screwdriver and carefully pry the valve off its seat, quickly remove the screwdriver allowing the valve to return to its seat. If the valve does not snap back unencumbered, then the valve will need to be removed from the valve body. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 4901 2. Once the valve is removed, inspect for any scratching or scoring. 3. If any scratching or scoring is found, then the fingernail test will need to be performed. Important: It has been found that in most cases that the scratches are not severe enough to catch your fingernail. 4. Using your fingernail, move over any scratches to see if your nail will catch on the scratch or score. - If your nail catches in the scratches, the valve will need to be replaced. - If your nail does not catch in the scratches, continue with the next step. 6. Important: Clean the valve body with the machined side down so debris may escape. 7. Clean the valve and bore using brake cleaner. 8. Blow off with shop air. 9. To verify free movement of the valve, dip the valve into clean ATF and install the valve back into the appropriate bore. The valve should move freely. If the valve moves freely, in most cases the valve body will function properly when reinstalled. 10. Reassemble and retest Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 02-07-30-013E > May > 05 > A/T - 4T65E Poor Performance/Harsh Shifts/DTC's Set > Page 4902 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse Valve Body: All Technical Service Bulletins A/T - 4T65-E, No Reverse Hot/Slips in Reverse Bulletin No.: 04-07-30-033 Date: August 04, 2004 TECHNICAL Subject: No Reverse Hot, Transaxle Slips In Reverse When Hot, Bump In Reverse Hot (Retighten Valve Body Bolt (379) and Replace Channel Plate Gasket) Models: 2003-2004 Cars with 4T65-E Transaxle (RPO's MN3, MN7, M15 or M76) Condition Some customers may comment that the vehicle slips in reverse when hot, no reverse when hot, or they feel a bump when shifted into reverse when hot. Cause There are multiple possible causes. Listed below are some of the possible causes: ^ Low Transaxle fluid level. ^ Reverse Servo Cover snap ring out of retaining groove. ^ Reverse Servo Piston seal rolled or cut. ^ Channel Plate flatness out of specification. ^ Channel Plate alignment holes improper depth. ^ Valve Body bolt (379) incorrectly torqued. Correction Follow the procedure below for diagnostic tips and repair procedures. 1. Inspect the reverse cover retaining ring for proper seating/retention. ^ If the ring is incorrectly seated, reset the retaining ring. ^ If the retaining ring is properly seated, continue with the next step. 2. Perform a transaxle line pressure check in reverse. This will test the reverse servo piston seal for leaks. ^ If the line pressure test is out of specification, inspect/repair the reverse servo piston seal. Refer to: - Reverse Servo Replacement w/3.4L Engine SI Document ID # 1485540 - Reverse Servo Replacement w/3.8L Engine SI Document ID # 1485543 ^ If the line pressure test is within specification, continue with the next step. 3. Remove the transaxle side cover. Refer to the appropriate SI Document. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4907 4. Inspect valve body bolt (379) for breakaway torque of 16 N.m (11 lb ft). ^ If valve body bolt (379) is found loose, replace the channel plate gaskets, P/N 24206391, and retighten the valve body. ^ If the valve body bolt is found not to be loose, continue with the next step. 5. For additional reverse diagnostic information, refer to Slips in Reverse or No Reverse SI Document ID # 54866. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 04-07-30-033 > Aug > 04 > A/T - 4T65-E, No Reverse Hot/Slips in Reverse > Page 4908 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-07-30-029 > Jul > 03 > A/T - 4T65E Internal Updates Valve Body: All Technical Service Bulletins A/T - 4T65E Internal Updates Bulletin No.: 03-07-30-029 Date: July 15, 2003 INFORMATION Subject: Changes for 2004 Model Year for 4T65E Transaxle - Internal Changes to Valve Body, Spacer Plate and Channel Plate and Touch Activated Power (TAP) Models: 2004 Buick Century, LeSabre, Park Avenue, Regal, Rendezvous 2004 Chevrolet Impala, Monte Carlo, Venture 2004 Oldsmobile Silhouette 2004 Pontiac Aztek, Bonneville, Grand Prix, Montana with 4T65E Transaxle (RPOs MN3, MN7, M15, M76) Important: This bulletin mainly deals with the features of the new Touch Activated Power feature of the 4T65E transaxle, which is only available on the supercharged Grand Prix. However, it is important for technicians to familiarize themselves with the differences between the TAP-equipped transaxle and the non-TAP equipped transaxle. There are several components of the transaxle that are unique to TAP. These components are NOT INTERCHANGEABLE with the same components on a non-TAP equipped 4T65E transaxle. If the correct parts are not used, serious driveability concerns could result. The purpose of this bulletin is to introduce new features of the 4T65E transaxle for the 2004 model year. Valve Body, Spacer Plate and Channel Plate. Valve Body, Spacer Plate and Channel Plate The internal changes to the 4T65E transmission are in the valve body, spacer plate and the channel plate. These parts are unique to the Touch Activated Power (TAP)-equipped 4T65E transmission. (TAP is only available on supercharged Grand Prix models.) A non-TAP transmission has a different valve body, spacer plate and channel plate. DO NOT MIX THE PARTS. If incorrect parts are installed, there will be shifting concerns. Any test drives should include TAP-Shift(TM) operation. Channel Plate and Valve Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-07-30-029 > Jul > 03 > A/T - 4T65E Internal Updates > Page 4913 The TAP channel plate and valve is shown on the left-hand side of the illustration. The non-TAP channel plate and valve is shown on the right. Spacer Plate The new TAP spacer plate has three notches in the lower right corner. The new non-TAP spacer plate has no notches in the lower right corner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-07-30-029 > Jul > 03 > A/T - 4T65E Internal Updates > Page 4914 The new TAP-equipped vehicle also has different fourth clutch plates, with fiber on one side and steel on the other. A non-TAP vehicle will have normal fiber and steel plates for the fourth clutch. The 2/1 manual band is made from a different material for TAP-Shift(TM) applications. This material will handle more stress than the normal 2/1 band in the other models. The transaxle filter has also changed to improve oil pickup. The new filter will back service any past model 4T65E and its use is required on all Century, Regal, Impala, Monte Carlo and Grand Prix vehicles for 2004. Performance Shifting with TAP-Shift(TM) (Available ONLY on Supercharged Grand Prix Models) If the vehicle is equipped with the 3800 V6 supercharged engine, it may have a console gearshift with a MANUAL (M) position. The other gearshift positions available are PARK (P), REVERSE (R), NEUTRAL (N) and AUTOMATIC OVERDRIVE (D). These positions operate as they have in the past. While in the MANUAL (M) position, the auto trans manual shift position switches, or paddles (located on the steering wheel), can be used to upshift or downshift the transaxle, under certain circumstances. Steering Wheel Shift Position Switch and Head Up Display Symbol While in the MANUAL (M) mode, push either paddle once to upshift to the next gear. Pull either paddle once to downshift to the next gear. To use the system, select MANUAL (M) while stopped, with the engine running. The vehicle will begin moving in first gear upon acceleration. For better control in icy or slippery conditions, the vehicle may start out in second gear, rather than in first. The upshift indicator light on the instrument panel, or the upshift symbol on the Head-Up Display (HUD) (if equipped), is given as a prompt to use the TAP-Shift(TM) paddle. These prompts to upshift as needed will be given throughout acceleration. If upshifting does not occur when prompted, the vehicle speed will be limited Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 03-07-30-029 > Jul > 03 > A/T - 4T65E Internal Updates > Page 4915 to protect the engine. Press the accelerator quickly while driving in the highest gear to make the transaxle automatically downshift. The transaxle will also automatically downshift as the vehicle decelerates and comes to a stop. When a paddle is pushed or pulled, a chime will sound when the vehicle cannot respond to a transaxle gear change. The system will not allow either an upshift or a downshift if the vehicle speed is too fast or slow, nor will it allow a start from third or higher gear. The MANUAL (M) gear can also be selected while the vehicle is already moving. The current transaxle position will continue to be displayed on the Driver Information Center (DIC) and HUD (if equipped). The transaxle upshifts and downshifts can be done using the TAP-Shift(TM) paddles as described previously. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 01-07-30-036H > Jan > 09 > A/T Control - DTC P0756 Diagnostic Tips Valve Body: All Technical Service Bulletins A/T Control - DTC P0756 Diagnostic Tips INFORMATION Bulletin No.: 01-07-30-036H Date: January 29, 2009 Subject: Diagnostic Tips for Automatic Transmission DTC P0756, Second, Third, Fourth Gear Start Models: 2009 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with 4L60-E, 4L65-E or 4L70E Automatic Transmission (RPOs M30, M32 or M70) Supercede: This bulletin is being revised to add the 2009 model year and add details regarding spacer plates. Please discard Corporate Bulletin Number 01-07-30-036G (Section 07 - Transmission/Transaxle). Some dealership technicians may have difficulty diagnosing DTC P0756, 2-3 Shift Valve Performance on 4L60-E, 4L65-E or 4L70E automatic transmissions. As detailed in the Service Manual, when the PCM detects a 4-3-3-4 shift pattern, DTC P0756 will set. Some customers may also describe a condition of a second, third or fourth gear start that may have the same causes but has not set this DTC yet. Below are some tips when diagnosing this DTC: ^ This is a performance code. This means that a mechanical malfunction exists. ^ This code is not set by electrical issues such as a damaged wiring harness or poor electrical connections. Electrical problems would cause a DTC P0758, P0787 or P0788 to set. ^ The most likely cause is chips/debris plugging the filtered AFL oil at orifice # 29 on the top of the spacer plate (48). This is a very small hole and is easily plugged by a small amount of debris. It is important to remove the spacer plate and inspect orifice # 29 and the immediate area for the presence of chips/debris. Also, the transmission case passage directly above this orifice and the valve body passage directly below should be inspected and cleaned of any chips/debris. For 2003 and newer vehicles the spacer plate should be replaced. The service replacement spacer plate is a bonded style with gaskets and solenoid filter screens bonded to the spacer plate. These screens can help to prevent plugging of orifice # 29 caused by small debris or chips. ^ This code could be set if the 2-3 shift valve (368) were stuck or hung-up in its bore. Inspect the 2-3 shift valve (368) and the 2-3 shuttle valve (369) for free movement or damage and clean the valves, the bore and the valve body passages. ^ This code could be set by a 2-3 shift solenoid (367b) if it were cracked, broken or leaking. Refer to Shift Solenoid Leak Test in the appropriate Service Manual for the leak test procedure. Based on parts return findings, a damaged or leaking shift solenoid is the least likely cause of this condition. Simply replacing a shift solenoid will not correct this condition unless the solenoid has been found to be cracked, broken or leaking. It is important to also refer to the appropriate Service Manual or Service Information (SI) for further possible causes of this condition. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 03-07-30-029 > Jul > 03 > A/T - 4T65E Internal Updates Valve Body: All Technical Service Bulletins A/T - 4T65E Internal Updates Bulletin No.: 03-07-30-029 Date: July 15, 2003 INFORMATION Subject: Changes for 2004 Model Year for 4T65E Transaxle - Internal Changes to Valve Body, Spacer Plate and Channel Plate and Touch Activated Power (TAP) Models: 2004 Buick Century, LeSabre, Park Avenue, Regal, Rendezvous 2004 Chevrolet Impala, Monte Carlo, Venture 2004 Oldsmobile Silhouette 2004 Pontiac Aztek, Bonneville, Grand Prix, Montana with 4T65E Transaxle (RPOs MN3, MN7, M15, M76) Important: This bulletin mainly deals with the features of the new Touch Activated Power feature of the 4T65E transaxle, which is only available on the supercharged Grand Prix. However, it is important for technicians to familiarize themselves with the differences between the TAP-equipped transaxle and the non-TAP equipped transaxle. There are several components of the transaxle that are unique to TAP. These components are NOT INTERCHANGEABLE with the same components on a non-TAP equipped 4T65E transaxle. If the correct parts are not used, serious driveability concerns could result. The purpose of this bulletin is to introduce new features of the 4T65E transaxle for the 2004 model year. Valve Body, Spacer Plate and Channel Plate. Valve Body, Spacer Plate and Channel Plate The internal changes to the 4T65E transmission are in the valve body, spacer plate and the channel plate. These parts are unique to the Touch Activated Power (TAP)-equipped 4T65E transmission. (TAP is only available on supercharged Grand Prix models.) A non-TAP transmission has a different valve body, spacer plate and channel plate. DO NOT MIX THE PARTS. If incorrect parts are installed, there will be shifting concerns. Any test drives should include TAP-Shift(TM) operation. Channel Plate and Valve Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 03-07-30-029 > Jul > 03 > A/T - 4T65E Internal Updates > Page 4925 The TAP channel plate and valve is shown on the left-hand side of the illustration. The non-TAP channel plate and valve is shown on the right. Spacer Plate The new TAP spacer plate has three notches in the lower right corner. The new non-TAP spacer plate has no notches in the lower right corner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 03-07-30-029 > Jul > 03 > A/T - 4T65E Internal Updates > Page 4926 The new TAP-equipped vehicle also has different fourth clutch plates, with fiber on one side and steel on the other. A non-TAP vehicle will have normal fiber and steel plates for the fourth clutch. The 2/1 manual band is made from a different material for TAP-Shift(TM) applications. This material will handle more stress than the normal 2/1 band in the other models. The transaxle filter has also changed to improve oil pickup. The new filter will back service any past model 4T65E and its use is required on all Century, Regal, Impala, Monte Carlo and Grand Prix vehicles for 2004. Performance Shifting with TAP-Shift(TM) (Available ONLY on Supercharged Grand Prix Models) If the vehicle is equipped with the 3800 V6 supercharged engine, it may have a console gearshift with a MANUAL (M) position. The other gearshift positions available are PARK (P), REVERSE (R), NEUTRAL (N) and AUTOMATIC OVERDRIVE (D). These positions operate as they have in the past. While in the MANUAL (M) position, the auto trans manual shift position switches, or paddles (located on the steering wheel), can be used to upshift or downshift the transaxle, under certain circumstances. Steering Wheel Shift Position Switch and Head Up Display Symbol While in the MANUAL (M) mode, push either paddle once to upshift to the next gear. Pull either paddle once to downshift to the next gear. To use the system, select MANUAL (M) while stopped, with the engine running. The vehicle will begin moving in first gear upon acceleration. For better control in icy or slippery conditions, the vehicle may start out in second gear, rather than in first. The upshift indicator light on the instrument panel, or the upshift symbol on the Head-Up Display (HUD) (if equipped), is given as a prompt to use the TAP-Shift(TM) paddle. These prompts to upshift as needed will be given throughout acceleration. If upshifting does not occur when prompted, the vehicle speed will be limited Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 03-07-30-029 > Jul > 03 > A/T - 4T65E Internal Updates > Page 4927 to protect the engine. Press the accelerator quickly while driving in the highest gear to make the transaxle automatically downshift. The transaxle will also automatically downshift as the vehicle decelerates and comes to a stop. When a paddle is pushed or pulled, a chime will sound when the vehicle cannot respond to a transaxle gear change. The system will not allow either an upshift or a downshift if the vehicle speed is too fast or slow, nor will it allow a start from third or higher gear. The MANUAL (M) gear can also be selected while the vehicle is already moving. The current transaxle position will continue to be displayed on the Driver Information Center (DIC) and HUD (if equipped). The transaxle upshifts and downshifts can be done using the TAP-Shift(TM) paddles as described previously. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4928 Ball Check Valves Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Oil Pump Replacement Valve Body: Service and Repair Oil Pump Replacement Oil Pump Replacement Removal Procedure 1. Remove the case side cover. 2. Use a flat-bladed tool to disconnect the electrical connectors from the solenoid valves (315A, 315B, 322, 334 and 440), the TFP manual valve position switch (395) and the temperature sensor (391). Important: Do NOT remove the bolt (205) that holds the oil pump together. 3. Remove the oil pump bolts (206, 207). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Oil Pump Replacement > Page 4931 4. Remove the oil pump (200) from the valve body (300). 5. Inspect the oil pump. Installation Procedure 1. Install the oil pump (200) to the valve body (300). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Oil Pump Replacement > Page 4932 2. Install the oil pump bolts (206, 207). ^ Tighten the M6 X 1.0 X 85 bolts (207) to 12 Nm (106 inch lbs.). ^ Tighten the M6 X 1.0 X 95 bolts (206) to 16 Nm (12 ft. lbs.). 3. Connect the electrical connectors to the solenoid valves (315A, 315B, 322, 334 and 440), the TFP manual valve position switch (395) and the temperature sensor (391). 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Oil Pump Replacement > Page 4933 Valve Body: Service and Repair Control Valve Body Replacement Control Valve Body Replacement Tools Required ^ J 36850 Transjel Lubricant Removal Procedure 1. Remove the case side cover. 2. Remove the oil pump. 3. Remove the valve body bolts (374-381, 384). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Oil Pump Replacement > Page 4934 4. Remove the valve body (300) while keeping the spacer plate (370) with the transaxle. 5. Remove the ball check valves (372 and 373) from the valve body. 6. Remove the spacer plate (370) and the gasket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Oil Pump Replacement > Page 4935 7. Remove the ball check valves (372) from the case cover. 8. Inspect each check valve seat in the spacer plate (370) for excessive peening. Place a ball check valve (372) on each seat and use a flashlight in order to look for visible light between the valve and the seat. 9. Inspect the valve body. Installation Procedure Notice: Do NOT use any type of grease to retain parts during the assembly of this unit. Using greases other than the recommended assembly lube changes the transaxle fluid characteristics. Using greases other than the recommended assembly lube causes undesirable shift conditions and/or filter clogging. Use TRANSJEL J 36850 or equivalent during the assembly of this unit. 1. Install the ball check valves (372) into the case cover. Use the J 36850 to retain the ball check valves in their proper locations. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Oil Pump Replacement > Page 4936 2. Install the gasket and the spacer plate (370). 3. Install the ball check valves (372 and 373) into the valve body. Use the J 36850 to retain the ball check valves in their proper locations. Important: Do NOT use impact type tools on the valve body or on the oil pump. 4. Install the gasket (371) and the valve body (300). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Oil Pump Replacement > Page 4937 Notice: Refer to Fastener Notice in Service Precautions. 5. Install the valve body bolts (374-381, 384). ^ Tighten the M6 X 1.0 X 20 bolt (381) to 8 Nm (70 inch lbs.). ^ Tighten the M6 X 1.0 X 30 bolt (376) to 12 Nm (106 inch lbs.) ^ Tighten the M6 X 1.0 X 45 bolt (377) to 12 Nm (106 inch lbs.). ^ Tighten the M6 X 1.0 X 55 bolt (378) to 11 Nm (97 inch lbs.). ^ Tighten the M6 X 1.0 X 60 bolt (3751 to 12 Nm (106 inch lbs.) ^ Tighten the M6 X 1.0 X 65 bolt (374) to 12 Nm (106 inch lbs.). ^ Tighten the M6 X 1.0 X 85 bolt (384) to 11 Nm (97 inch lbs.). ^ Tighten the M6 X 1.0 X 90 bolt (379) to 11 Nm (97 inch lbs.). ^ Tighten the M6 X 1.0 X 90 bolt (380) to 25 Nm (18 ft. lbs.). 6. Install the oil pump. 7. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Oil Pump Replacement > Page 4938 Valve Body: Service and Repair Oil Weir Replacement Oil Weir Replacement Removal Procedure 1. Remove the case side cover. 2. Remove the oil reservoir weir (27). Installation Procedure 1. Install the oil reservoir weir (27). 2. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-022B > Oct > 03 > A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set Wiring Harness: Customer Interest A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set Bulletin No.: 02-07-30-022B Date: October 20, 2003 TECHNICAL Subject: Service Engine Soon (SES) Light On With DTCs P0716 and/or P0717, P0730, P0753, P0758, P1860, P1887, or other Miscellaneous Transmission Trouble Codes Set (Repair Wiring at Transaxle Wiring Pass-thru Connector) Models: 2000-2004 Buick Century, LeSabre, Park Avenue, Regal 2003-2004 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2004 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2004 Chevrolet Classic 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Aurora 2000-2004 Oldsmobile Alero, Silhouette 2000-2004 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2004 Pontiac Aztek 2000 Toyota Cavalier with 4T65-E, 4T40-E or 4T45-E Transaxle (RPOs MN3, MN7, M15, M76, MN4, MN5) Supercede: This bulletin is being revised to add the 2004 model year as well as the Chevrolet Classic model. Please discard Corporate Bulletin Number 02-07-30-022A (Section 07-Transmission/Transaxle). Condition Some customers may comment that the Service Engine Soon (SES) indicator is illuminated and that while the light is illuminated, transmission shifts are extremely harsh. Cause These types of conditions may be caused by an intermittent connection at the transaxle 20-way connector to the wiring harness interface. Correction If a DTC was recorded and the Freeze Frame and Failure Records back it up, a problem existed at one time with the wiring and/or the connectors between the transaxle and the PCM. Therefore, a thorough inspection and/or repair of the wiring harness at the transaxle 20-way connector for one or more of the following conditions may be warranted. ^ The wiring harness is stretched too tightly or other components are pressing on the connector body itself causing a downward pressure on the connector body and possible intermittent contact of the wiring terminals. Ensure proper clearance to any other components and wiring (i.e. hoses, battery cables, etc.). ^ The terminals are not fully seated into the cavity of the connector body. ^ The male terminals in the transaxle portion of the connector may be in the wrong position (i.e. bent). ^ The female terminals may be loose and are not making proper contact. Check the tension with the proper terminal tester from the GM Terminal Test Kit J 35616-A or J 35616-92. If the tension is low, replace the terminal. Do not try to re-form the terminal. ^ The crimp of the terminal to the wire may not be satisfactory (i.e. loose, over insulation, etc.). ^ The wiring connector is not properly seated and locked in position. Ensure proper seating of the connector into the transaxle and that the connector is properly locked in place. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 02-07-30-022B > Oct > 03 > A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set > Page 4947 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-022B > Oct > 03 > A/T MIL/SES Lamp ON/Multiple A/T DTC's Set Wiring Harness: All Technical Service Bulletins A/T - MIL/SES Lamp ON/Multiple A/T DTC's Set Bulletin No.: 02-07-30-022B Date: October 20, 2003 TECHNICAL Subject: Service Engine Soon (SES) Light On With DTCs P0716 and/or P0717, P0730, P0753, P0758, P1860, P1887, or other Miscellaneous Transmission Trouble Codes Set (Repair Wiring at Transaxle Wiring Pass-thru Connector) Models: 2000-2004 Buick Century, LeSabre, Park Avenue, Regal 2003-2004 Buick Rendezvous 2000-2001 Chevrolet Lumina 2000-2004 Chevrolet Cavalier, Impala, Malibu, Monte Carlo, Venture 2004 Chevrolet Classic 2000-2002 Oldsmobile Intrigue 2000-2003 Oldsmobile Aurora 2000-2004 Oldsmobile Alero, Silhouette 2000-2004 Pontiac Bonneville, Grand Am, Grand Prix, Montana, Sunfire 2001-2004 Pontiac Aztek 2000 Toyota Cavalier with 4T65-E, 4T40-E or 4T45-E Transaxle (RPOs MN3, MN7, M15, M76, MN4, MN5) Supercede: This bulletin is being revised to add the 2004 model year as well as the Chevrolet Classic model. Please discard Corporate Bulletin Number 02-07-30-022A (Section 07-Transmission/Transaxle). Condition Some customers may comment that the Service Engine Soon (SES) indicator is illuminated and that while the light is illuminated, transmission shifts are extremely harsh. Cause These types of conditions may be caused by an intermittent connection at the transaxle 20-way connector to the wiring harness interface. Correction If a DTC was recorded and the Freeze Frame and Failure Records back it up, a problem existed at one time with the wiring and/or the connectors between the transaxle and the PCM. Therefore, a thorough inspection and/or repair of the wiring harness at the transaxle 20-way connector for one or more of the following conditions may be warranted. ^ The wiring harness is stretched too tightly or other components are pressing on the connector body itself causing a downward pressure on the connector body and possible intermittent contact of the wiring terminals. Ensure proper clearance to any other components and wiring (i.e. hoses, battery cables, etc.). ^ The terminals are not fully seated into the cavity of the connector body. ^ The male terminals in the transaxle portion of the connector may be in the wrong position (i.e. bent). ^ The female terminals may be loose and are not making proper contact. Check the tension with the proper terminal tester from the GM Terminal Test Kit J 35616-A or J 35616-92. If the tension is low, replace the terminal. Do not try to re-form the terminal. ^ The crimp of the terminal to the wire may not be satisfactory (i.e. loose, over insulation, etc.). ^ The wiring connector is not properly seated and locked in position. Ensure proper seating of the connector into the transaxle and that the connector is properly locked in place. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 02-07-30-022B > Oct > 03 > A/T MIL/SES Lamp ON/Multiple A/T DTC's Set > Page 4953 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4959 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4960 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4961 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4966 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4967 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4968 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4969 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4970 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4971 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 4976 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4982 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4983 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 4984 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4989 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4990 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4991 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4992 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4993 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 4994 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 4999 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 5000 Wiring Harness: Service and Repair Wiring Harness Replacement Removal Procedure 1. Remove the case side cover. 2. Use a small flat-bladed tool in order to remove the wiring harness from the solenoid valve (315A, 315B, 322, 334 and/or 440), TFP manual valve position switch (395) and the temperature sensor (391). 3. Remove the wiring harness (224). Installation Procedure 1. Install the wiring harness (224). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Wiring Harness, A/T > Component Information > Technical Service Bulletins > Page 5001 2. Install the wiring harness to the solenoid valve (315A, 315B, 322, 334 and/or 440), TFP manual valve position switch (395) and the temperature sensor (391). 3. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > System Information > Technical Service Bulletins > M/T - Hydraulic Clutch Bleeding Procedure Improvement Clutch Hydraulic System: Technical Service Bulletins M/T - Hydraulic Clutch Bleeding Procedure Improvement Bulletin No.: 01-07-31-002B Date: November 01, 2006 INFORMATION Subject: Improved Bleeding Procedure for Hydraulic Clutch Release System Models: 2007 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2007 and Prior Chevrolet and GMC 6-7F T-Series Medium Duty Tilt Cab Models 2007 and Prior Isuzu F-Series Medium Duty Tilt Cab Models 2006-2007 HUMMER H3 Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-07-31-002A (Section 07 - Transmission/Transaxle). This bulletin is being issued to inform dealers of an improved procedure to aid in the ease of bleeding the clutch hydraulic system for the above listed vehicles. This procedure can be used anytime air is introduced into the hydraulic system. Following this procedure may also reduce the number of unnecessary parts replaced for low clutch pedal reserve and high shift effort. Verify that all the lines and fittings are dry and secure. Clean the dirt and grease from the reservoir cap in order to ensure that no foreign substances enter the system. Remove the reservoir cap. Fill the reservoir to the proper level with the required fluid. Attach the J 43485 (Adapter) to the J 35555 (Mity Vac), or equivalent. Brake fluid will deteriorate the rubber on J 43485. Use a clean shop cloth to wipe away the fluid after each use. Place and hold the adapter on the reservoir filler neck to ensure a tight fit. In some cases, the adapter will fit into the reservoir opening. Apply a vacuum of 51-68 kPa (15-20 hg) and remove the adapter. Refill the reservoir to the proper level. Repeat Steps 6 and 7. If needed, refill the reservoir and continue to pull a vacuum until no more bubbles can be seen in the reservoir or until the fluid level no longer drops. The vehicle will move if started in gear before the Actuator Cylinder is refilled and operational. Start the vehicle the first time in neutral to help prevent personal injury from vehicle movement and see if the transmission will shift easily into gear. Pump the clutch pedal until firm (to refill actuator cylinder). Add additional fluid if needed. Test drive vehicle to ensure proper operation. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Continuously Variable Transmission/Transaxle, CVT > Shift Interlock, CVT > Component Information > Technical Service Bulletins > A/T - Shift Lock Control Feature Function Shift Interlock: Technical Service Bulletins A/T - Shift Lock Control Feature Function Bulletin No.: 03-07-30-043A Date: May 25, 2006 INFORMATION Subject: Information Regarding Automatic Transmission Shift Lock Control Function Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Transmission Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 03-07-30-043 (Section 07 - Transmission/Transaxle). This bulletin is being issued to better explain how the Automatic Transmission Shift Lock Control (formerly known as Brake Transmission Shift Interlock (BTSI)) feature is intended to operate. Revised wording regarding the shift lock control system began appearing in the Owner Manuals beginning with the 2004 model year. The shift lock control feature was intended to prevent drivers from shifting out of Park with the vehicle running without the brakes applied. However, if the ignition switch is in the Accessory (ACC) position, it may be possible on some vehicles to move the shift lever out of Park WITHOUT first activating the brake. The shift lock control system is ONLY active when the ignition switch is in the RUN or ON position. This means that when the ignition switch is in the RUN or ON position, the shift lever cannot be moved out of the Park position without activating the brake. Some owners may feel that the shift lock control system prevents an unattended child from moving the vehicle. Please stress to owners, as stated in the Owner Manual, that children should NEVER be left unattended in a vehicle, even if the ignition key has been removed from the vehicle. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair Axle Shaft: Service and Repair Wheel Drive Shaft Replacement ^ Tools Required J 2619-01 Slide Hammer - J 29794 Axle Shaft Remover Extension - J 33008-A Axle Shaft Remover - J 42129 Hub Spindle Remover Removal Procedure Caution: To prevent personal injury and/or component damage, do not allow the weight of the vehicle to load the front wheels, or attempt to operate the vehicle, when the wheel drive shaft(s) or wheel drive shaft nut(s) are removed. To do so may cause the inner bearing race to separate, resulting in damage to brake and suspension components and loss of vehicle control. Notice: Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the wheel and the tire. 3. Remove the stabilizer shaft link. 4. Remove the front wheel drive shaft nut (2). Insert a drift or a flat-bladed tool (1) into the caliper and the rotor to prevent the rotor from turning. 5. Disconnect the outer tie rod assembly from the steering knuckle. 6. Separate the ball joint from the steering knuckle. 7. Separate the front wheel drive axle from the front wheel drive shaft bearing using the J42129. The nut can be partially re-installed to protect the threads. 8. If necessary, remove the left front wheel drive axle (1) from the transaxle. If necessary, remove the right front wheel drive axle (2) from the transaxle. Use the J 33008-A, the J 29794 and the J2619-O1 to separate the axle from the transaxle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Service and Repair > Page 5017 Installation Procedure 1. Install the front wheel drive axle (1, 2) into the transaxle. 2. Verify that the front wheel drive shaft retaining ring is properly seated: ^ Grasp the inner housing and pull the inner housing outward. Do not pull on the front wheel drive axle shaft. ^ The front wheel drive axle will remain in place when the front wheel drive shaft retaining ring is properly seated. 3. Install the front wheel drive axle into the front wheel drive shaft bearing. 4. Connect the ball joint to the steering knuckle. 5. Connect the outer tie rod assembly to the steering knuckle. Notice: Refer to Fastener Notice in Service Precautions. 6. Install a new front wheel drive shaft nut. Insert a drift or a flat-bladed tool into the caliper and the rotor to prevent the rotor from turning. ^ Tighten the nut to 160 Nm (118 ft. lbs.). 7. Install the stabilizer shaft link. 8. Install the wheel and the tire. 9. Lower the vehicle. 10. Inspect the transaxle fluid level. 11. Inspect the wheel alignment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement Constant Velocity Joint: Service and Repair Wheel Drive Shaft Inner Joint and Seal Replacement Wheel Drive Shaft Inner Joint and Seal Replacement ^ Tools Required J 41048 Drive Axle Swage Ring Clamp - J 8059 Snap Ring Pliers - J 35910 Drive Axle Seal Clamp Pliers Disassembly Procedure Notice: Do not cut through the wheel drive shaft inboard seal during service. Cutting through the seal may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint. 1. Disconnect the swage ring from the halfshaft bar using a hand grinder to cut through the ring taking care not to damage the halfshaft bar. 2. Remove the large seal retaining clamp (2) from the tripot joint with side cutters. Discard the large seal retaining clamp (2). 3. Separate the inboard seal from the trilobal tripot bushing (3) at the large diameter. 4. Slide the seal away from the joint along the halfshaft bar. 5. Remove the housing (1) from the tripot joint spider and the halfshaft bar (2). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 5022 6. Spread spacer ring (2) using J 8059. 7. Slide the spacer ring (3) and the tripot joint spider (2) back on the halfshaft bar (4). 8. Remove the halfshaft bar retaining ring (1) from the groove on the halfshaft bar. 9. Slide tripot joint spider assembly (2) off of the halfshaft bar (4). 10. Clean the tripot joint spider assembly (2) and the housing thoroughly with cleaning solvent. 11. Remove all traces of old grease and any contaminates. Dry all the parts. 12. Remove the trilobal tripot bushing from the housing. Discard the old trilobal tripot bushing. 13. Remove the spacer ring (3) and the seal from the halfshaft bar (4). 14. Inspect the following parts for damage or wear: ^ The inboard seal ^ The tripot joint spider assembly (2) ^ The housing Assembly Procedure 1. Install the new swage ring (2) on the neck of the inboard seal (1). Do not swage. 2. Slide the halfshaft inboard seal (1) onto the halfshaft bar. 3. Position the neck of the halfshaft inboard seal (1) in the seal groove (3) on the halfshaft bar. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 5023 4. Position the inboard end of the halfshaft assembly (1) using J41048. Notice: Do not cut through the wheel drive shaft inboard seal during service. Cutting through the seal may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint. 5. Align the swage ring (2) by performing the following steps: 5.1. Place the top half of J 41048 on the lower half of J41048. Important: Align the following items: ^ The inboard seal (1) ^ The housing ^ The swage ring (2) 5.2. Insert the bolts. Notice: Refer to Fastener Notice in Service Precautions. 5.3. Tighten the bolts by hand until snug. ^ Tighten each bolt 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed. 5.4. Loosen the bolts. 5.5. Separate the dies. 5.6. Check the swage ring (2) for any "lip" deformities. If present, place the ring (2) back into the J41048 ensuring the swage ring (2) covers the whole swaging area. 5.7. Re-swage the swage ring (2). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 5024 6. Install the spacer ring (3) on the halfshaft bar (4) and beyond the second groove. Important: Ensure that the counterbored face of the tripot joint spider (2) faces the end of the halfshaft bar (4). 7. Slide the tripot joint spider assembly (2) toward the spacer ring (3) as far as it will go on the halfshaft bar (4). 8. Install the halfshaft bar retaining ring (1) in the groove of the halfshaft bar (4) using J 8059. 9. Slide the tripot joint spider assembly (2) towards the end of the halfshaft bar (4). 10. Reseat the spacer ring (3) in the groove on the halfshaft bar (4). 11. Place approximately half of the grease from the service kit in the inboard seal. Use the remainder of the grease to repack the housing. 12. Install the new trilobal tripot bushing to housing. Ensure the trilobal tripot bushing is flush with the face of the housing. 13. Position the larger new clamp on the inboard seal. 14. Slide the housing over the tripot joint spider assembly on the halfshaft bar. 15. Slide the large diameter of the inboard seal, with the larger clamp in place, over the outside of the trilobal tripot bushing and locate the lip of the seal in the groove. Important: The inboard seal (2) must not be dimpled, stretched out or out of shape in any way. If the inboard seal (2) is not shaped correctly, carefully insert a thin flat blunt tool (no sharp edges) between the large seal opening and the trilobal tripot bushing to equalize the pressure. Shape the inboard seal properly by hand. Remove the tool. 16. Position the joint assembly at the proper vehicle dimension. Dimension a= 125.7 mm (5 inch). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 5025 Important: Align the following items while latching: ^ The inboard seal ^ The housing (2) ^ The large seal retaining clamp (3) 17. Crimp the seal retaining clamp (3) with J 35910. ^ Crimp the clamp (3) to 174 Nm (130 ft. lbs.). 18. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Dimension a= 2.3 mm (3/32 inch) maximum. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 5026 Constant Velocity Joint: Service and Repair Wheel Drive Shaft Outer Joint and Seal Replacement Wheel Drive Shaft Outer Joint and Seal Replacement ^ Tools Required J 41048 Drive Axle Swage Ring Clamp - J 8059 Snap Ring Pliers - J 35910 Drive Axle Seal Clamp Pliers Disassembly Procedure 1. Remove the large seal retaining clamp from the CV joint with a side cutter. Discard the seal retaining clamp. Notice: Do not cut through the wheel drive shaft inboard seal during service. Cutting through the seal may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint. 2. Use a hand grinder to cut through the swage ring in order to remove the swage ring. 3. Separate the halfshaft outboard seal from CV joint outer race (1) at large diameter. 4. Slide the seal (5) away from joint along halfshaft bar (4). 5. Wipe the grease from the face of the CV joint inner race t2). 6. Spread the ears on the race retaining ring (3) with J 8059. 7. Remove the CV joint assembly (1) from the halfshaft bar t4) 8. Remove the halfshaft outboard seal (5) from the halfshaft bar (4). 9. Discard the old outboard seal. 10. Place a brass drift against the CV joint cage (1). 11. Tap gently on the brass drift with a hammer in order to tilt the cage (1). 12. Remove the first chrome alloy ball (2) when the CV joint cage (1) tilts. 13. Tilt the CV joint cage (1) in the opposite direction to remove the opposing chrome alloy ball (2). 14. Repeat this process to remove all six of the balls. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 5027 15. Pivot the CV joint cage (4) and the inner race 90 degrees to the center line of the outer race (2). At the same time, align the cage windows (3) with the lands of the outer race. 16. Lift out the cage (4) and the inner race. 17. Remove the inner race (1) from the cage (2) by rotating the inner race (1) upward. 18. Clean the following items thoroughly with cleaning solvent. Remove all traces of old grease and any contaminates. ^ The inner and outer race assemblies ^ The CV joint cage ^ The chrome alloy balls 19. Dry all the parts. 20. Check the CV joint assembly for the following items: ^ Unusual wear ^ Cracks ^ Damage 21. Replace any damaged parts. 22. Clean the halfshaft bar. Use a wire brush to remove any rust in the seal mounting area (grooves). Assembly Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 5028 1. Install the new swage ring (2) on the neck of the outboard seal (1). Do not swage. 2. Slide the outboard seal (1) onto the halfshaft bar and position the neck of the outboard seal (1) in the seal groove on the halfshaft bar. The largest groove below the sight groove on the halfshaft bar is the seal groove (3). 3. The swage ring is swaged using J 41048 by the following method: 3.1. Position the outboard end of the halfshaft assembly (1) in J41048. 3.2. Align the swage ring. 3.3. Place the top half of J 410480 the lower half of J41048. Notice: Do not cut through the wheel drive shaft inboard seal during service. Cutting through the seal may damage the sealing surface of the housing and the tripot bushing. Damage to the sealing surface may lead to water and dirt intrusion and premature wear of the constant velocity joint. Important: Align the following items during this procedure: ^ The outboard seal (1) ^ The housing ^ The swage ring Notice: Refer to Fastener Notice in Service Precautions. 3.4. Insert the bolts (2) and tighten by hand until snug. ^ Each bolt 180 degrees at a time using a ratchet wrench. Alternate between each bolt until both sides are bottomed. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 5029 4. Loosen the bolts and separate the dies. 5. Check swaged ring (2) for any "lip" deformities. If present, place the ring (2) back into the J41048 making sure the ring covers the whole swaging area. Then re-swage the ring. 6. Put a light coat of grease from the service kit on the ball grooves of the inner race and the outer race. 7. Hold the inner race 90 degrees to centerline of cage with the lands of the inner race (1) aligned with the windows of the cage (2) and insert the inner race into the cage. 8. Hold the cage and the inner race 90 degrees to centerline of the outer race (1) and align the cage windows (3) with the lands of the outer race. Important: Be sure that the retaining ring side of the inner race faces the halfshaft bar. 9. Place the cage and the inner race into the outer race. 10. Insert the first chrome ball then tilt the cage in the opposite direction to insert the opposing ball. 11. Repeat this process until all 6 balls are in place. 12. Place approximately half the grease from the service kit inside the outboard seal and pack the CV joint with the remaining grease. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint > Component Information > Service and Repair > Wheel Drive Shaft Inner Joint and Seal Replacement > Page 5030 13. Push the CV joint (2) onto the halfshaft bar (1) until the retaining ring is seated in the groove on the halfshaft bar. Important: The outboard seal (1) must not be dimpled, stretched or out of shape in any way. If the outboard seal (1) is not shaped correctly, equalize the pressure in the outboard seal (1) and shape the seal properly by hand. 14. Slide large diameter of the outboard seal (1) with the large seal retaining clamp (2) in place over the outside of the CV joint outer race (3) and locate the seal lip in the groove on the CV joint outer race. 15. Crimp the seal retaining clamp (1) using J35910. ^ Crimp the clamp (1) to 174 Nm (130 ft. lbs.). 16. Check the gap dimension on the clamp ear. Continue tightening until the gap dimension is reached. Dimension a= 1.9 mm (5/64 inch). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Constant Velocity Joint Boot > Component Information > Specifications Constant Velocity Joint Boot: Specifications Drive Axle Seal Clamp 174 N-m Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > Customer Interest for Seals and Gaskets: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: Customer Interest A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 08-07-30-009B > May > 08 > A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks Seals and Gaskets: All Technical Service Bulletins A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5047 Seals and Gaskets: By Symptom Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5048 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Technical Service Bulletin # 08-07-30-009B Date: 080501 A/T - 4T80E, Slips in Gear/L/H Axle Seal Leaks TECHNICAL Bulletin No.: 08-07-30-009B Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Seals and Gaskets, Drive Axles > System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > Page 5049 Date: May 01, 2008 Subject: HYDRA-MATIC(R) Front Wheel Drive 4T80-E (MH1) Left Front Axle Seal Leak, Transmission Slips in Gear (Replace Third Clutch Housing with Revised Service Part) Models: 2001-2008 GM Passenger Cars with HYDRA-MATIC(R) Front Wheel Drive 4T80-E Automatic Transmission (RPO - MH1) Supercede: This bulletin is being updated to revise the Warranty Information. Please discard Corporate Bulletin Number 08-07-30-009A (Section 07 - Transmission/Transaxle). Condition Some customers may comment on a transmission oil leak and/or that the transmission slips in gear. Cause An oil leak may be caused by bushing wear in the third clutch housing, causing excessive fluid build-up at axe sea. Correction Important: DO NOT replace the transmission for above concerns. Replace the third clutch housing with service P/N 8682114, which has revised bushing material to extend life and reduce left front axle seal leaks. Refer to Automatic/Transaxle - 4T80-E Transmission Off-Vehicle Repair Instructions for the replacement of the third clutch housing in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Front Wheel Bearing/Hub Bolts ............................................................................................................................................................. 130 Nm (96 ft. lbs.) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 5054 Wheel Bearing: Fluid Type Specifications FRONT WHEEL BEARINGS Wheel bearing lubricant meeting requirements of NLGI # 2, Category GC or GC-LB (GM Part No. U.S. 1051344, in Canada 993037). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 5055 Wheel Bearings Diagnosis Step 1-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Bearing/Hub Replacement - Front ^ Tools Required J 42129 Wheel Hub Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Disconnect the wheel speed sensor electrical connector (2), if equipped. 4. Remove the wheel speed sensor electrical connector from the bracket, if equipped. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5058 5. Remove the front wheel drive shaft nut (2). Insert a drift or flat bladed tool (1) into the caliper and rotor to prevent from turning. 6. Remove the brake rotor. 7. Use 3 wheel nuts in order to attach the J 42129 to the wheel bearing/hub. 8. Use the J 42129 in order to push the wheel drive shaft out of the wheel bearing/hub. 9. Remove and DISCARD the wheel bearing/hub bolts. Remove the J 42129 from the hub. Important: Ensure that the wheel drive shaft outer seal/boot is not damaged. 10. Remove the wheel bearing/hub and splash shield-noting the position of the shield for reinstallation. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5059 1. Install the wheel bearing/hub with the splash shield as noted during removal. Caution: These fasteners MUST be replaced with new fasteners anytime they become loose or are removed. Failure to replace these fasteners after they become loose or are removed may cause loss of vehicle control and personal injury. Notice: Refer to Fastener Notice in Service Precautions. 2. Install NEW wheel bearing/hub bolts. ^ Tighten the NEW wheel bearing/hub bolts to 130 Nm (96 ft. lbs.). 3. Install the brake rotor and caliper. 4. Install the front wheel drive shaft nut. Insert a drift on a flat bladed tool into caliper and rotor to prevent the rotor from turning. ^ Tighten the front wheel drive shaft nut to 160 Nm (118 ft. lbs.). Important: Ensure that the connector clip engages the bracket properly. 5. Install the wheel speed sensor electrical connector to the bracket, if equipped. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5060 6. Connect the wheel speed sensor electrical connector (2), if equipped. 7. Install the tire and wheel. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5061 Wheel Bearing: Service and Repair Rear Wheel Bearing/Hub Replacement - Rear Removal Procedure Important: The wheel bearing in the rear wheel hub is integrated into one unit. The hub is non-serviceable. If the hub and/or bearing is damaged, replace the complete hub and bearing assembly. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tires and wheels. 3. Remove the brake rotor. 4. Remove the ABS electrical connector from the wheel speed sensor (1), if equipped. 5. Remove the park brake cable from the park brake actuator. 6. Remove the mounting bolts from the rear bearing/hub. 7. Remove the wheel bearing/hub and park brake assembly from the knuckle. 8. Remove the park brake actuator from the rear wheel bearing/hub. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5062 1. Install the park brake actuator to the rear wheel bearing/hub. 2. install the wheel bearing/hub and park brake assembly to the knuckle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the wheel bearing/hub-to-knuckle bolts. ^ Tighten the bolts to 75 Nm (55 ft. lbs.). 4. Install the park brake cable to the park brake actuator. 5. Install the ABS electrical connector to the wheel speed sensor (1), if equipped. 6. Install the brake rotor. 7. Install the tires and wheels. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Drive Shaft Nut ........................................................................................................................... ................................................... 160 N.m (118 lb ft) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications Flex Plate: Specifications Flywheel Bolts ..................................................................................................................................... ................................ 15 Nm (11 ft. lbs.) + 50 degrees Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5070 Flex Plate: Service and Repair Engine Flywheel Replacement - Tools Required J 45059 Torque Angle Meter - J 37096 Flywheel Holder Removal Procedure 1. Remove the transaxle. 2. Use the J 37096 to prevent the flywheel from rotating. 3. Loosen the 8 engine flywheel bolts. 4. Remove 7 of the 8 engine flywheel bolts, leaving 1 bolt at the top of the crankshaft rotation. 5. Firmly grasp the engine flywheel and remove the remaining bolt. Do not drop the engine flywheel when removing the final bolt. 6. Remove the engine flywheel. Installation Procedure 1. Install the engine flywheel. 2. Use the J 37096 to prevent the flywheel from rotating. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the new engine flywheel bolts. 3.1. Tighten the bolts to 15 Nm (11 ft. lbs.). 3.2. Use the J 45059 to rotate the bolts an additional 50 degrees. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications > Page 5071 Important: The crankshaft end play must be held in one direction during this check. 4. Use the following procedure to measure engine flywheel runout: 4.1. Install a dial indicator on the engine block and check the engine flywheel runout at three attaching bosses. 4.2. If the runout is not within the specification and cannot be corrected, replace the engine flywheel. 5. Install the transaxle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Diagrams PRNDL Lamp Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information > Technical Service Bulletins > Manual Transmission - M/T Operating Characteristics Manual Transmission/Transaxle: Technical Service Bulletins Manual Transmission - M/T Operating Characteristics INFORMATION Bulletin No.: 03-07-29-004G Date: December 15, 2010 Subject: Manual Transmission Operating Characteristics Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2009 and Prior Chevrolet and GMC Medium Duty Trucks 2006-2010 HUMMER H3 with Manual Transmission Supercede: This bulletin is being revised to add the 2011 model year and to add Cold Operation information. Please discard Corporate Bulletin Number 03-07-29-004F (Section 07 Transmission/Transaxle). Important Even though this bulletin attempts to cover operating characteristics of manual transmissions, it cannot be all inclusive. Be sure to compare any questionable concerns to a similar vehicle and if possible, with similar mileage. Even though many of the conditions are described as characteristics and may not be durability issues, GM may attempt to improve specific issues for customer satisfaction. The purpose of this bulletin is to assist in identifying characteristics of manual transmissions that repair attempts will not change. The following are explanations and examples of conditions that will generally occur in all manual transmissions. All noises will vary between transmissions due to build variation, type of transmission (usually the more heavy duty, the more noise), type of flywheel and clutch, level of insulation, etc. Basic Information Many transmission noises are created by the firing pulses of the engine. Each firing pulse creates a sudden change in angular acceleration at the crankshaft. These changes in speed can be reduced with clutch damper springs and dual mass flywheels. However, some speed variation will make it through to the transmission. This can create noise as the various gears will accel and decel against each other because of required clearances. Cold Operation Manual transmission operation will be affected by temperature because the transmission fluid will be thicker when cold. The thicker fluid will increase the amount of force needed to shift the transmission when cold. The likelihood of gear clash will also increase due to the greater time needed for the synchronizer assembly to perform its function. Therefore when the transmission is cold, or before it has reached operating temperature, quick, hard shifts should be avoided to prevent damage to the transmission. Gear Rattle Rattling or grinding (not to be confused with a missed shift type of grinding, also described as a combustion knock type of noise) type noises usually occur while operating the engine at low RPMs (lugging the engine). This can occur while accelerating from a stop (for example, a Corvette) or while operating at low RPMs while under a load (for example, Kodiak in a lower gear and at low engine speed). Vehicles equipped with a dual-mass flywheel (for example, a 3500 HD Sierra with the 6-speed manual and Duramax(R)) will have reduced noise levels as compared to vehicles without (for example, a 4500 Kodiak with the 6-speed manual and Duramax(R)). However, dual-mass flywheels do not eliminate all noise. Neutral Rattle There are often concerns of rattle while idling in neutral with the clutch engaged. This is related to the changes in angular acceleration described earlier. This is a light rattle, and once again, vehicles with dual mass flywheels will have reduced noise. If the engine is shut off while idling in neutral with the clutch engaged, the sudden stop of the engine will create a rapid change in angular acceleration that even dual mass flywheels cannot compensate. Because of the mass of all the components, this will create a noise. This type of noise should not be heard if the clutch is released (pedal pushed to the floor). Backlash Backlash noise is created when changing engine or driveline loading. This can occur when accelerating from a stop, coming to a stop, or applying and releasing the throttle (loading and unloading the driveline). This will vary based on vehicle type, build variations, driver input, vehicle loading, etc. and is created from the necessary clearance between all of the mating gears in the transmission, axle(s) and transfer case (if equipped). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Component Information > Technical Service Bulletins > Manual Transmission - M/T Operating Characteristics > Page 5084 Shift Effort Shift effort will vary among different style transmissions and synchronizer designs. Usually the more heavy duty the transmission, the higher the shift effort because of the increased mass of the components. Shift effort can also be higher in cold weather because the fluid will be thicker. Medium duty transmissions will not shift as quickly as a Corvette transmission. To reduce shift effort, do not attempt to rush the shift - allow the synchronizers to work as designed. Shifting harder will only increase the chance of rushing past the synchronizer leading to grinding while shifting. Non-Synchronized Gears Some light duty truck transmissions in 1st gear (creeper-gear) and reverse gears in various transmissions, along with all gears in some medium duty transmissions, may be non-synchronized. This means there is not a mechanism to match input and output shaft speeds to allow for a smooth shift. This function is left up to the driver. This can be noticed if a shift into 1st or reverse is attempted while the vehicle is rolling or before the input shaft stops rotating leading to a gear grind. The grinding can be reduced by coming to a complete stop and pausing for a moment before shifting into the 1st or reverse gear. Some slight grinding can be expected. In medium duty non-synchronized transmissions, the driver must match input shaft (engine) speed to output shaft (driveshaft) speed with every shift. This can be accomplished by double clutching, or by using other methods. If the driver is not able to perform this function properly, there will be gear grinding with each improperly completed shift. Driver training may be required to correct this condition. Clutch brakes are used in medium duty non-synchronized transmissions to allow a shift into gear at a stop. The clutch brake is used to stop the input shaft from spinning, allowing a shift into gear at a stop without grinding. The clutch brake is activated by pressing the clutch pedal all the way to the floor. When the clutch brake is used, it is possible to have a blocked shift with the vehicle stationary. If this occurs, engage the clutch slightly to rotate the input gear to allow the shift. The clutch brake is intended to only be used while at a stop. Care must be taken to not activate the clutch brake while shifting between gears. This could lead to excessive grinding or a blocked or missed shift. Skip Shift Currently, the Cadillac CTS-V, Pontiac GTO, Chevrolet Corvette and Camaro SS (other models may follow) equipped with the 6-speed manual transmission have a feature referred to as a "skip-shift." This feature only allows a shift from 1st to 4th gear when the indicator lamp is illuminated on the dash. Dealers cannot disable this feature as it was established to help meet fuel economy standards. The conditions for this feature are: engine coolant at normal operating temperature, vehicle speed of 24-31 km/h (15-19 mph), 21% or less throttle being used (refer to Service Information or the Owner Manual for more details.) Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams TCC Brake Switch Wiring Harness Side C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 5093 Automatic Transmission Fluid Pressure Manual Valve Position Switch Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 5094 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the transaxle wiring harness. 3. Remove the control valve body bolts (375, 379, 381) that mount the fluid pressure manual valve position switch to the control valve body (300). Important: When removing the TFP switch handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 4. Carefully remove the fluid pressure manual valve position switch (395) 5. Inspect the fluid pressure manual valve position switch (395) for the following conditions ^ Damaged electrical connector terminals ^ Damaged seals ^ Damaged switch membranes ^ Debris on the switch membranes Installation Procedure Important: When installing the TFP switch handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 1. Carefully install the fluid pressure manual valve position switch (395). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the control valve body bolts (375, 379, 381) that mount the TFP switch to the control valve body (300). ^ Tighten the control valve body bolt (375) to 12 Nm (106 inch lbs.). ^ Tighten the control valve body bolt (379) to 16 Nm (106 inch lbs.). ^ Tighten the control valve body bolt (381) to 8 Nm (70 inch lbs.). 3. Connect the transaxle wiring harness. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 5095 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5099 Input Speed Sensor Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5100 Transmission Speed Sensor: Service and Repair Input Speed Sensor Replacement Removal Procedure 1. Remove the case side cover 2. Disconnect the input speed sensor electrical connector. 3. Remove the input speed sensor retaining clip (441). 4. Remove the input speed sensor (440). 5. Inspect the input speed sensor (440) for the following conditions: ^ Damaged or missing magnet ^ Damaged housing ^ Bent or missing electrical terminals ^ Damaged speed sensor clip (441) Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5101 1. Install the input speed sensor (440). 2. Install the input speed sensor retaining clip (441). 3. Connect the input speed sensor electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 5105 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 5106 Transmission Fluid Temperature Sensor Connector Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement Transmission Temperature Sensor/Switch: Service and Repair Thermo Element Replacement Thermo Element Replacement Tools Required ^ J 34094-A Thermo Element Height Gage Removal Procedure 1. Raise and support the vehicle. 2. Remove the oil pan. 3. Remove the thermo element pins (120, 123) and the washers. 4. Remove the thermo element (121) and the thermo element plate (122). Installation Procedure 1. Use the J 34094-A to set the middle thermo pin (123). 2. Install the new thermo element plate (122). 3. Install the pin (120) and the washer. 4. Use the J 34094-A to set the height of the pin and the washer furthest from the accumulator. 5. Use the J 34094-A to set the height of the second pin (120) and the washer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement > Page 5109 6. Install the thermo element (121) between the two pins (120). The V in the thermo element (121) must contact the thermo element plate (122). 7. Install the oil pan. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement > Page 5110 Transmission Temperature Sensor/Switch: Service and Repair Fluid Temperature Sensor Replacement Fluid Temperature Sensor Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the wiring harness assembly tram the fluid temperature sensor (391) 3. Remove the fluid temperature sensor (391). Installation Procedure 1. install the fluid temperature sensor (391). 2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5117 Pressure Control Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Pressure Regulating Solenoid, A/T > Component Information > Locations > Page 5118 Pressure Regulating Solenoid: Service and Repair Pressure Control Solenoid (PCS) Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the Pressure Control Solenoid (PCS) electrical connector. 3. Remove the PCS retaining clip (314E). 4. Remove the PCS (322). Installation Procedure 1. Install the PCS (322). 2. Install the PCS retaining clip (314E). 3. Connect the PCS electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations Shift Interlock Solenoid: Locations Lower Center Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5122 Console And Center Of Floor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Locations > Page 5123 A/T Shift Lock Control Solenoid Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift Shift Interlock Solenoid: Service and Repair With Floor Shift Automatic Transmission Shift Lock Actuator Replacement (Floor Shift) Removal Procedure 1. Disconnect the negative battery cable. 2. Remove the center console. 3. Disconnect the automatic shift lock actuator electrical connector. 4. Remove the automatic shift lock actuator from the pivot point (1), the base of the shift lock control and the vehicle. Installation Procedure 1. Install the automatic shift lock actuator to the base of the shift lock control and the pivot point (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift > Page 5126 2. Connect the automatic shift lock actuator electrical connector. 3. Install the center console. 4. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift > Page 5127 Shift Interlock Solenoid: Service and Repair With Column Shift Automatic Transmission Shift Lock Actuator Replacement (Column Shift) Removal Procedure 1. Remove the knee bolster bracket. 2. Disconnect the automatic shift lock actuator electrical connector. 3. Remove the actuator from the steering column ball studs. Installation Procedure 1. Install the automatic shift lock control actuator to the steering column ball studs. 2. Connect the automatic shift lock actuator electrical connector. 3. Place the column in the neutral position. 4. Adjust the automatic shift lock actuator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Interlock Solenoid > Component Information > Service and Repair > With Floor Shift > Page 5128 4.1. Pull out the tab (1) on the adjuster block side (2) of the actuator. 4.2. Press on the adjuster block (2) in order to compress the internal adjuster spring and disengage the adjuster teeth. Slide the adjuster block as far away from the actuator as possible. 4.3./105GLock in place by pushing in on the tab (1). 5. Inspect the actuator ^ The actuator must lock the shift lever clevis when you place the clevis in the park position. ^ If you can move the shift lever without pressing on the brake pedal. readjust the actuator. 6. Install the knee bolster bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications Shift Solenoid Valve State and Gear Ratio Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Specifications > Page 5132 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Diagrams > 1-2 Shift Solenoid Valve Connector, Wiring Harness Side > Page 5135 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement Shift Solenoid: Service and Repair 1-2 Shift Solenoid Valve Replacement 1-2 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the 1-2 shift solenoid electrical connector. 3. Remove the 1-2 shift solenoid retaining clip (314D) 4. Remove the 1-2 shift solenoid (315A). Installation Procedure 1. Install the 1-2 shift solenoid (315A). 2. Install the 1-2 shift solenoid retaining clip (314D). 3. Connect the 1-2 shift solenoid electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Service and Repair > 1-2 Shift Solenoid Valve Replacement > Page 5138 Shift Solenoid: Service and Repair 2-3 Shift Solenoid Valve Replacement 2-3 Shift Solenoid Valve Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the 2-3 shift solenoid electrical connector. 3. Remove the 2-3 shift solenoid retaining clip (314C). 4. Remove the 2-3 shift solenoid (315B) and the O-ring (316). Installation Procedure 1. Install the O-ring (316) and the 2-3 shift solenoid (315B). 2. Install the 2-3 shift solenoid retaining clip (314C). 3. Connect the 2-3 shift solenoid electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Locations > Page 5142 Torque Converter Clutch Pulse Width Modulated Solenoid Valve Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch (TCC) Solenoid Torque Converter Clutch (TCC) Solenoid Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the Torque Converter Clutch (TCC) solenoid electrical connector. 3. Remove the TCC solenoid retaining clip (314) 4. Remove the TCC solenoid (315). Installation Procedure 1. install the TCC solenoid (315). 2. Install the TCC solenoid retaining clip (314). 3. Connect the TCC solenoid electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 5145 Torque Converter Clutch Solenoid: Service and Repair Torque Converter Clutch Pulse Width Modulation Solenoid Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect and reposition the electrical connectors from the following: ^ If equipped internal mode switch ^ 2 - 3 Shift solenoid valve assembly (315B) ^ Automatic transaxle fluid pressure manual valve position switch assembly (395) Important: Do NOT remove the bolt (205) that holds the oil pump together. 3. Remove the oil pump bolts (206, 207). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 5146 4. Remove the oil pump (200) from the valve body (300). 5. Disconnect the Torque Converter Clutch Pulse Width Modulation (TCC PWM) solenoid electrical connector. 6. Remove the TCC PWM solenoid retaining clip (314F). 7. Remove the TCC PWM solenoid (334). Installation Procedure 1. Install the TCC PWM solenoid (334). 2. Install the TCC PWM solenoid retaining clip (314F). 3. Connect the TCC PWM solenoid electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 5147 4. Install the oil pump (200) to the valve body (300). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the oil pump bolts (206, 207). Tighten ^ Tighten the bolts (207) to 12 Nm (106 inch lbs.). ^ Tighten the bolts (206) to 16 Nm (12 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Torque Converter Clutch Solenoid, A/T > Component Information > Service and Repair > Torque Converter Clutch (TCC) Solenoid > Page 5148 6. Reposition and connect the electrical connectors to the following: ^ Automatic transaxle fluid pressure manual valve position switch assembly (395) ^ 2 - 3 Shift solenoid valve assembly (315B) ^ If equipped internal mode switch 7. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Diagrams PRNDL Lamp Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Brake Switch - TCC > Component Information > Diagrams TCC Brake Switch Wiring Harness Side C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 5165 Automatic Transmission Fluid Pressure Manual Valve Position Switch Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 5166 Fluid Pressure Sensor/Switch: Service and Repair Transmission Fluid Pressure (TFP) Manual Valve Position Switch Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the transaxle wiring harness. 3. Remove the control valve body bolts (375, 379, 381) that mount the fluid pressure manual valve position switch to the control valve body (300). Important: When removing the TFP switch handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 4. Carefully remove the fluid pressure manual valve position switch (395) 5. Inspect the fluid pressure manual valve position switch (395) for the following conditions ^ Damaged electrical connector terminals ^ Damaged seals ^ Damaged switch membranes ^ Debris on the switch membranes Installation Procedure Important: When installing the TFP switch handle the switch carefully, the fluid pressure manual valve position switch is very delicate. 1. Carefully install the fluid pressure manual valve position switch (395). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the control valve body bolts (375, 379, 381) that mount the TFP switch to the control valve body (300). ^ Tighten the control valve body bolt (375) to 12 Nm (106 inch lbs.). ^ Tighten the control valve body bolt (379) to 16 Nm (106 inch lbs.). ^ Tighten the control valve body bolt (381) to 8 Nm (70 inch lbs.). 3. Connect the transaxle wiring harness. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Fluid Pressure Sensor/Switch, A/T > Component Information > Locations > Page 5167 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5171 Input Speed Sensor Connector, Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5172 Transmission Speed Sensor: Service and Repair Input Speed Sensor Replacement Removal Procedure 1. Remove the case side cover 2. Disconnect the input speed sensor electrical connector. 3. Remove the input speed sensor retaining clip (441). 4. Remove the input speed sensor (440). 5. Inspect the input speed sensor (440) for the following conditions: ^ Damaged or missing magnet ^ Damaged housing ^ Bent or missing electrical terminals ^ Damaged speed sensor clip (441) Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Locations > Page 5173 1. Install the input speed sensor (440). 2. Install the input speed sensor retaining clip (441). 3. Connect the input speed sensor electrical connector. 4. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications Transmission Fluid Temperature (TFT) Sensor Specifications Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 5177 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Specifications > Page 5178 Transmission Fluid Temperature Sensor Connector Wiring Harness Side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement Transmission Temperature Sensor/Switch: Service and Repair Thermo Element Replacement Thermo Element Replacement Tools Required ^ J 34094-A Thermo Element Height Gage Removal Procedure 1. Raise and support the vehicle. 2. Remove the oil pan. 3. Remove the thermo element pins (120, 123) and the washers. 4. Remove the thermo element (121) and the thermo element plate (122). Installation Procedure 1. Use the J 34094-A to set the middle thermo pin (123). 2. Install the new thermo element plate (122). 3. Install the pin (120) and the washer. 4. Use the J 34094-A to set the height of the pin and the washer furthest from the accumulator. 5. Use the J 34094-A to set the height of the second pin (120) and the washer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement > Page 5181 6. Install the thermo element (121) between the two pins (120). The V in the thermo element (121) must contact the thermo element plate (122). 7. Install the oil pan. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Service and Repair > Thermo Element Replacement > Page 5182 Transmission Temperature Sensor/Switch: Service and Repair Fluid Temperature Sensor Replacement Fluid Temperature Sensor Replacement Removal Procedure 1. Remove the case side cover. 2. Disconnect the wiring harness assembly tram the fluid temperature sensor (391) 3. Remove the fluid temperature sensor (391). Installation Procedure 1. install the fluid temperature sensor (391). 2. Connect the wiring harness assembly to the with fluid temperature sensor (391). 3. Install the case side cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5188 Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5189 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Notice: To prevent equipment damage, never connect or disconnect the wiring harness connection from the EBCM with the ignition switch in the ON position. 1. Turn the ignition switch to the OFF position. 2. Remove the fuel injector sight shield, 3.8 L engine only. 3. Remove the front fender upper diagonal brace. 4. Disconnect the accelerator and cruise control cable from the accelerator control cable bracket. 5. Disconnect the cruise control module from the left strut tower. It is not necessary to remove the cable from the module. Position the module and cables aside. 6. Remove the air cleaner intake duct. 7. Disengage the red locking tab (1) from connector lock tab. 8. Push down lock tab and then move sliding connector cover (2) to the open position. 9. Disconnect the EBCM harness connector. 10. Remove any dirt/debris from the assembly. 11. Remove the four EBCM to BPMV retainers. Important: Do not pry apart using a tool. Be careful not to damage BPMV surface. Important: Care must be taken not to damage the solenoid valves when the EBCM is removed from the BPMV. 12. Separate the EBCM from the BPMV by gently pulling apart until separated. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5190 1. Install the EBCM to the BPMV. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four retainers that attach the EBCM to BPMV. ^ Tighten the retainers to 5 Nm (44 inch lbs.). 3. Connect the EBCM harness connector. 4. Push down lock tab (1) and then move sliding connector cover (2) back in the home position to lock. 5. Reengage the red locking tab (1) to the connected lock tab. 6. Install the air cleaner intake duct. 7. Reposition the module and cables. Connect the cruise control module to the left strut tower. 8. Connect the accelerator and cruise control cable to the accelerator control cable bracket. 9. Install the front fender upper diagonal brace. 10. Install the fuel injector sight shield, 3.8 L engine only. 11. Turn the ignition switch to the RUN position, do not start engine. 12. Perform the Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Bracket Replacement Brake Pressure Modulator Valve (BPMV) Bracket Replacement Removal Procedure 1. Turn the Ignition switch to the OFF position. 2. Remove the 2 BPMV mounting bracket nuts (3) and one bolt located near the bottom and one nut (1) located at the top of the BPMV mounting bracket (4) to the strut tower. 3. Disconnect the ground strap between the EBCM assembly and the chassis. 4. Remove the BPMV mounting bracket (4) from the vehicle. 5. Remove BPMV and EBCM assembly (2) from the BPMV mounting bracket (4). Installation Procedure 1. Install the BPMV and EBCM assembly (2) to the BPMV mounting bracket (4). 2. Install the BPMV bracket (4) to the strut tower. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 1 bolt and 3 nuts that attach the BPMV mounting bracket (4) to the strut tower. ^ Tighten the lower 2 BPMV mounting bracket nuts (3) and bolt to 10 Nm (89 inch lbs.). ^ Tighten the top nut (1) for BPMV mounting bracket (4) to strut tower to 3 Nm (27 inch lbs.). 4. Reconnect the ground strap between the EBCM assembly and the chassis. 5. Turn the ignition switch to the RUN position, engine off. 6. Perform the Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 5195 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure Caution: For safety reasons, the Brake Pressure Modulator Valve (BPMV) must not be repaired, the complete unit must be replaced. With the exception of the EBCM/EBTCM, no screws may be loosened. If screws are loosened, it will not be possible to get the brake circuits leak-tight and personal injury may result. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Turn the ignition switch to the OFF position. 2. Remove the attaching bolts for the cruise control module. 3. Swing the cruise control module off to the side. 4. Disengage the red locking tab from the connector (1). 5. Push down lock tab (1) and then move sliding connector cover (2) to the open position. 6. Disconnect the EBCM harness connector. Important: Note the locations of the brake pipes in order to aid in installation. 7. Disconnect the brake pipes (1) from the BPMV (2). 8. Swing the 4 brakes pipes out of the way only after covering the open pipes to avoid dripping or being contaminated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 5196 9. Disconnect the master cylinder brake pipes (2) from the BPMV (4). 10. It is not necessary to remove the brake pipes (2) from the master cylinder (1). 11. Swing the 2 master cylinder brake pipes out of the way only after covering the open pipes to avoid dripping or being contaminated. 12. Remove the 2 BPMV mounting bracket nuts (3) and 1 bolt located near the bottom and one nut (1) located at the top of the BPMV mounting bracket (4) to the strut tower. 13. Disconnect the ground strap between the EBCM assembly and the chassis. 14. Remove the BPMV mounting bracket (4) and EBCM assembly (2) from the vehicle. 15. Remove the 4 bolts (3) that connect the BPMV (1) to the mounting bracket (2). 16. Remove EBCM if replacing the BPMV only. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 5197 1. Install EBCM onto the BPMV(1) if replacing the BPMV only. 2. Install BPMV and EBCM as an assembly (1) to the mounting bracket (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 4 bolts (3) that connects the BPMV assembly (1) to the mounting bracket (2). ^ Tighten the 4 bolts (3) that connect the BPMV (1) to the mounting bracket (2) to 10 Nm (89 inch lbs.). 4. Install the BPMV bracket (4) to the strut tower. 5. Install the 1 bolt and 3 nuts that attach the BPMV, mounting bracket (4) to the strut tower. ^ Tighten the lower 2 BPMV mounting bracket nuts (3) and bolt to 10 Nm (84 inch lbs.). ^ Tighten the top nut (1) for BPMV mounting bracket (4) to strut tower to 3 Nm (27 inch lbs.). Caution: Make sure brake pipes are correctly connected to brake pressure modulator valve. If brake pipes are switched by mistake wheel lockup will occur and personal injury may result The only two ways this condition can be detected are by using a Scan Tool or by doing an Antilock stop. Important: If a new BPMV is being installed, remove the shipping plugs from the valve openings during the next few steps when ready. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 5198 6. Install the master cylinder brake pipes (2) into the BPMV (4). ^ Tighten the master cylinder brake pipe fittings to 24 Nm (18 ft. lbs.). 7. Install the brake pipes (1) on the BPMV (2). ^ Tighten all 4 brake pipe fittings to 24 Nm (18 ft. lbs.). 8. Reconnect the ground strap between the EBCM assembly and the chassis. 9. Connect the EBCM harness connector. 10. Push down lock tab (1) and then move sliding connector cover (2) back in home position to lock. 11. Insert red locking tab back in place. 12. Reinstall the cruise control module. 13. When all procedures have been completed, the automated ABS bleed procedure is required. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Service and Repair Traction Control Switch: Service and Repair Traction Control Switch Replacement (Impala) Removal Procedure 1. If equipped with column shift, apply the parking brake. 2. If equipped with column shift, position the transaxle shift control indicator to 1. 3. Adjust the steering wheel for access. 4. Remove the ignition switch cylinder bezel. 5. Remove the LH instrument panel (IP) fuse block access opening cover. 6. Remove the LH IP cluster trim plate screws. 7. Remove the IP cluster trim plate for access. Start at the left side of the IP cluster trim plate, grasp the trim plate and carefully pull rearward. Disengage enough IP cluster trim plate retainers in order to gain access the traction control switch. 8. Disconnect the electrical connector (1) from the traction control switch (2). 9. Remove the traction control switch (1) from the IF, cluster trim plate (2). Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control Switch > Component Information > Service and Repair > Page 5202 1. Install the traction control switch (1) to the IP cluster trim plate (2). 2. Connect the electrical connector (1) to the traction control switch (2). 3. Align and carefully press the IP cluster trim plate into the IP trim pad. Make sure all of the retainers are fully engaged. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the LH IP cluster trim plate screws. ^ Tighten the IP cluster trim plate screws to 2 Nm (18 inch lbs.). 5. Install the LH instrument panel (IP) fuse block access opening covers. 6. Install the ignition switch cylinder bezel. 7. Return the steering wheel to the original position. 8. If equipped with a column shift, position the transaxle shift control indicator to Park. 9. If equipped with column shift, release the parking brake. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement - Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement - Front Wheel Speed Sensor Replacement - Front Removal Procedure Important: The front wheel speed sensors and rings are integral with the hub and bearing assemblies. If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. Do not service the harness pigtail individually because the harness pigtail is part of the sensor. 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting. 2. Remove the front tire and wheel assembly. 3. Disconnect the front wheel speed sensor jumper harness electrical connector (1). 4. Remove the hub and bearing assembly (2). Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement - Front > Page 5207 1. Install the hub and bearing assembly (2) to the vehicle. 2. Install the front wheel speed sensor jumper harness electrical connector (1). 3. Install the wheel and tire assembly. 4. Lower the vehicle. 5. Turn the ignition switch to the ON position with the engine off. 6. Perform the Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement - Front > Page 5208 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement - Rear Wheel Speed Sensor Replacement - Rear Removal Procedure Important: The rear wheel speed sensors and rings are integral with the hub and bearing assemblies. If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting. 2. Remove the rear tire and wheel assembly. 3. Disconnect the electrical connector from the rear wheel speed sensor. 4. Remove the hub and bearing assembly (1). Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement - Front > Page 5209 1. Install the hub and bearing assembly (1) to the vehicle. 2. Connect the electrical connector to the rear wheel speed sensor. 3. Install the wheel and tire assembly. 4. Lower the vehicle. 5. Turn the ignition switch to the ON position, with the engine off. 6. Perform the Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Bleeding the ABS System Perform a manual or pressure bleeding procedure. If the desired brake pedal height results are not achieved, perform the automated bleed procedure below. The procedure cycles the system valves and runs the pump in order to purge the air from the secondary circuits normally closed off during normal base brake operation and bleeding. The automated bleed procedure is recommended when air ingestion is suspected in the secondary circuits, or when the BPMV has been replaced. Automated Bleed Procedure Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove all four tire and wheel assemblies. 3. Inspect the brake system for leaks and visual damage. Refer to Brake Fluid Loss or Symptoms - Hydraulic Brakes. Repair or replace as needed. 4. Inspect the battery state of charge. 5. Install a scan tool. 6. Turn ON the ignition, with the engine OFF. 7. With the scan tool, establish communications with the EBCM. Select Special Functions. Select Automated Bleed from the Special Functions menu. 8. Bleed the base brake system. 9. Follow the scan tool directions until the desired brake pedal height is achieved. 10. If the bleed procedure is aborted, a malfunction exists. Perform the following steps before resuming the bleed procedure: ^ If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List and diagnose the appropriate DTC. ^ If the brake pedal feels spongy, perform the conventional brake bleed procedure again. 11. When the desired pedal height is achieved, press the brake pedal in order to inspect for firmness. 12. Remove the scan tool. 13. Install the tire and wheel assemblies. 14. Inspect the brake fluid level. 15. Road test the vehicle while inspecting that the pedal remains high and firm. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 5215 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left front hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT - wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated. Refer to Symptoms - Hydraulic Brakes. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 5216 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 35589-A Brake Pressure Bleeder Adapter Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add Delco Supreme II (R) (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, if cap removal is necessary. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder, (after all air has been purged from the front port of the master cylinder), loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II (R) (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J29532, or equivalent. Add Delco Supreme II (R) (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532, or equivalent, to the J 35589-A. 8. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 12. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II (R) (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 13. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 14. With the right rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the right rear hydraulic circuit), install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 12-13. 15. With the left front wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the left front hydraulic circuit), install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 12-13. 16. With the left rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the left rear hydraulic circuit), install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 12-13. 17. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 18. Close the J 29532, or equivalent, fluid tank valve, then disconnect the J 29532, or equivalent, from the J 35589-A. 19. Remove the J 35589-A from the brake master cylinder reservoir. 20. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II (R) (GM P/N 12377967) or equivalent DOT-3 brake fluid Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 5217 from a clean, sealed brake fluid container. 21. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 22. If the brake pedal feels spongy perform the following steps: 22.1. Inspect the brake system for external leaks. 22.2. If equipped with Antilock Brakes, using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 23. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 24. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 5218 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair Brake Pedal Assy: Service and Repair Brake Pedal Replacement Removal Procedure 1. Remove the left (IP) insulator. 2. Remove the BCM from the bracket and position aside. 3. Remove the stop lamp switch. 4. If equipped, remove the TCC/cruise release switch. 5. Remove the wiring harness clips from the bracket. 6. Remove the pushrod retaining clip from the brake pedal. 7. Remove the pushrod and washer from the brake pedal. 8. Remove the brake pedal nut and bolt. 9. Remove the brake pedal and bushings. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Service and Repair > Page 5222 1. Install the brake pedal and the bushings. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the brake pedal nut and bolt. ^ Tighten the brake pedal nut and bolt to 40 Nm (30 ft. lbs.). 3. Install the washer and pushrod to the brake pedal. 4. Install the pushrod retaining clip to the brake pedal. 5. Install the wiring harness clips to the bracket. 6. If equipped, install the TCC/cruise release switch. 7. Install the stop lamp switch. 8. Reposition and install the BCM into the retaining bracket. 9. Install the left IP insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5227 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5228 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5229 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5230 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5231 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5232 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5233 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5234 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5235 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5236 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5237 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5238 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5239 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5240 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5241 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5242 Brake Warning Indicator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5243 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5244 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5245 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5246 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5247 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5248 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5249 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5250 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5251 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5252 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5253 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5254 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5255 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5256 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5257 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5258 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5259 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5260 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5261 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5262 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5263 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5264 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5265 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5266 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5267 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5268 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5269 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 5270 Brake Warning System Schematics Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Recalls for Brake Caliper: > 04049 > Jun > 04 > Recall - Front Brake Caliper Tightening Torque Technical Service Bulletin # 04049 Date: 040601 Recall - Front Brake Caliper Tightening Torque File In Section: Product Recalls Bulletin No.: 04049 Date: June, 2004 PRODUCT SAFETY RECALL SUBJECT: FRONT BRAKE CALIPER BOLT TORQUE MODELS: 2004 CHEVROLET IMPALA, MONTE CARLO 2004 PONTIAC GRAND PRIX CONDITION General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 model year Chevrolet Impala and Monte Carlo, and Pontiac Grand Prix vehicles. Some of these vehicles may have left and right front wheel assemblies in which the two bolts that attach the front brake caliper to the steering knuckle were not tightened adequately. If too much movement occurs between the caliper bracket and knuckle, the bolt(s) may back out or fracture. Depending on whether one or both bolts back out or fracture, the result can be 1) locking of the affected wheel during braking and an abrupt steering input in the direction of the locked wheel, 2) reduced braking and noise from the affected wheel, or 3) severing of a brake hose, increased brake pedal travel, and reduced steering control. If this were to occur, it could result in a vehicle crash without prior warning. CORRECTION Dealers are to tighten both bolts to the specified torque. VEHICLES INVOLVED Involved are certain 2004 model year Chevrolet Impala and Monte Carlo, and Pontiac Grand Prix vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned, will not have a report available in GM DealerWorld. For Canada & IPC: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. PARTS INFORMATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Recalls for Brake Caliper: > 04049 > Jun > 04 > Recall - Front Brake Caliper Tightening Torque > Page 5280 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO Customer Special Order. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. CUSTOMER NOTIFICATION - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Recalls for Brake Caliper: > 04049 > Jun > 04 > Recall - Front Brake Caliper Tightening Torque > Page 5281 Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for removing, cleaning, and reinstalling the bolts that attach both front brake caliper mounting brackets to the knuckles. 1. Raise the vehicle on a suitable hoist and support as necessary. 2. Remove both front tire and wheel assemblies. Important Do not remove the brake caliper from the mounting bracket. 3. Remove the two bolts (2) attaching the left front caliper mounting bracket (1) to the knuckle. Do not remove the bracket and caliper from the knuckle. 4. Using a wire brush, clean any threadlocker from the threads on the two bolts. 5. Apply adhesive (threadlocker), GM P/N 89021297 (Canadian P/N 10953488) or equivalent, to the threads of both bolts. 6. Reinstall the two bolts into the bracket. Tighten Tighten the bolts to 170 N.m (125 ft lb). 7. Repeat the procedure on the right side front caliper mounting bracket bolts. 8. Install both front tire and wheel assemblies. Tighten Tighten the wheel nuts to 140 N.m (103 ft lb). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Recalls for Brake Caliper: > 04049 > Jun > 04 > Recall - Front Brake Caliper Tightening Torque > Page 5282 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Recalls for Brake Caliper: > 04049 > Jun > 04 > Recall - Front Brake Caliper Tightening Torque > Page 5283 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Recalls for Brake Caliper: > NHTSA04V287000 > Jun > 04 > Recall 04V287000: Caliper Mounting Bolt Torque Brake Caliper: Recalls Recall 04V287000: Caliper Mounting Bolt Torque DEFECT: Certain passenger vehicles were produced with lower than specified torque on both front brake calipers to steering knuckle attachment bolts. With improper torque, the clamp load at the joint may not be adequate to prevent movement between the caliper bracket and knuckle. Depending on whether one or both bolts backs out or fractures, the result can be locking of the affected wheel during braking and an abrupt steering input in the direction of the locked wheel, reduced braking and noise from the affected wheel, or severing of a brake hose, increased brake pedal travel, and reduced steering control. Reduced braking or steering control could cause a crash. REMEDY: Dealers are to tighten both bolts to the specified torque. The manufacturer has reported that owner notification began on July 6, 2004. Owners may contact Chevrolet at 1-800-630-2438 or Pontiac at 1-800-620-7668. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04049 > Jun > 04 > Recall Front Brake Caliper Tightening Torque Technical Service Bulletin # 04049 Date: 040601 Recall - Front Brake Caliper Tightening Torque File In Section: Product Recalls Bulletin No.: 04049 Date: June, 2004 PRODUCT SAFETY RECALL SUBJECT: FRONT BRAKE CALIPER BOLT TORQUE MODELS: 2004 CHEVROLET IMPALA, MONTE CARLO 2004 PONTIAC GRAND PRIX CONDITION General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 model year Chevrolet Impala and Monte Carlo, and Pontiac Grand Prix vehicles. Some of these vehicles may have left and right front wheel assemblies in which the two bolts that attach the front brake caliper to the steering knuckle were not tightened adequately. If too much movement occurs between the caliper bracket and knuckle, the bolt(s) may back out or fracture. Depending on whether one or both bolts back out or fracture, the result can be 1) locking of the affected wheel during braking and an abrupt steering input in the direction of the locked wheel, 2) reduced braking and noise from the affected wheel, or 3) severing of a brake hose, increased brake pedal travel, and reduced steering control. If this were to occur, it could result in a vehicle crash without prior warning. CORRECTION Dealers are to tighten both bolts to the specified torque. VEHICLES INVOLVED Involved are certain 2004 model year Chevrolet Impala and Monte Carlo, and Pontiac Grand Prix vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned, will not have a report available in GM DealerWorld. For Canada & IPC: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. PARTS INFORMATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04049 > Jun > 04 > Recall Front Brake Caliper Tightening Torque > Page 5293 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO Customer Special Order. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. CUSTOMER NOTIFICATION - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04049 > Jun > 04 > Recall Front Brake Caliper Tightening Torque > Page 5294 Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for removing, cleaning, and reinstalling the bolts that attach both front brake caliper mounting brackets to the knuckles. 1. Raise the vehicle on a suitable hoist and support as necessary. 2. Remove both front tire and wheel assemblies. Important Do not remove the brake caliper from the mounting bracket. 3. Remove the two bolts (2) attaching the left front caliper mounting bracket (1) to the knuckle. Do not remove the bracket and caliper from the knuckle. 4. Using a wire brush, clean any threadlocker from the threads on the two bolts. 5. Apply adhesive (threadlocker), GM P/N 89021297 (Canadian P/N 10953488) or equivalent, to the threads of both bolts. 6. Reinstall the two bolts into the bracket. Tighten Tighten the bolts to 170 N.m (125 ft lb). 7. Repeat the procedure on the right side front caliper mounting bracket bolts. 8. Install both front tire and wheel assemblies. Tighten Tighten the wheel nuts to 140 N.m (103 ft lb). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04049 > Jun > 04 > Recall Front Brake Caliper Tightening Torque > Page 5295 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04049 > Jun > 04 > Recall Front Brake Caliper Tightening Torque > Page 5296 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > NHTSA04V287000 > Jun > 04 > Recall 04V287000: Caliper Mounting Bolt Torque Brake Caliper: All Technical Service Bulletins Recall 04V287000: Caliper Mounting Bolt Torque DEFECT: Certain passenger vehicles were produced with lower than specified torque on both front brake calipers to steering knuckle attachment bolts. With improper torque, the clamp load at the joint may not be adequate to prevent movement between the caliper bracket and knuckle. Depending on whether one or both bolts backs out or fractures, the result can be locking of the affected wheel during braking and an abrupt steering input in the direction of the locked wheel, reduced braking and noise from the affected wheel, or severing of a brake hose, increased brake pedal travel, and reduced steering control. Reduced braking or steering control could cause a crash. REMEDY: Dealers are to tighten both bolts to the specified torque. The manufacturer has reported that owner notification began on July 6, 2004. Owners may contact Chevrolet at 1-800-630-2438 or Pontiac at 1-800-620-7668. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement Brake Caliper: Service and Repair Brake Caliper Bracket Replacement Front Brake Caliper Bracket Replacement - Front Removal Procedure Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics wire or equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the front brake pads. 3. Remove the caliper bracket bolts (2). 4. Remove the caliper bracket (1). Installation Procedure Important: To ensure that the proper clamp load will be present when installed. It is imperative that the threads on the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of all debris and inspected before proceeding with installation. 1. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the knuckle. 2. Apply THREADLOCKER, GM P/N 12345493 (Canadian P/N 10953488) or equivalent, to the threads of the brake caliper bracket bolts (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the caliper bracket (1) with the bracket bolts (2). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5303 ^ Tighten the caliper bracket bolts to 180 Nm (133 ft. lbs.). 4. Install the front brake pads. 5. Install the caliper. Rear Brake Caliper Bracket Replacement - Rear Removal Procedure Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics wire or equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the rear brake pads. 3. Remove the caliper bracket bolts (2). 4. Remove the caliper bracket (1). Installation Procedure Important: To ensure that the proper clamp load will be present when installed. It is imperative that the threads on the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of all debris and inspected before proceeding with installation. 1. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the knuckle. 2. Apply THREADLOCKER, GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the brake caliper bracket bolts (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the caliper bracket (1) with the bracket bolts (2). ^ Tighten the caliper bracket bolts to 115 Nm (85 ft. lbs.). 4. Install the rear brake pads. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5304 5. Install the caliper. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5305 Brake Caliper: Service and Repair Brake Caliper Overhaul Front Brake Caliper Overhaul - Front ^ Tools Required J 35777 Caliper Piston Seal Installer Removal Procedure 1. Remove the front brake caliper from the vehicle. Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. 2. Remove the brake caliper piston from the caliper bore by, directing low pressure compressed air into the caliper bore through the fluid inlet hole. 3. Using a small wooden or plastic tool, remove the caliper dust boot seal (2) from the seal counterbore in the caliper (1) and discard the boot seal. 4. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore and discard the piston seal. 5. Remove the bleeder valve (5) and cap (6) from the caliper (1). Important: Do not use abrasives to clean the brake caliper piston. 6. Clean the brake caliper, piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 7. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered air. 8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion. 9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5306 10. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 11. Inspect the caliper piston for cracks, scoring, and/or damage to the finished surface area. Replace the caliper piston if any of these conditions exist. Installation Procedure 1. Lubricate the new piston seal with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667) or equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container. 2. Install the lubricated, new piston seal into the caliper bore. 3. Install the caliper piston into the caliper bore. Press the piston to the bottom of the bore. 4. Install the new piston dust boot seal over the piston. 5. Use J 35777 to fully seat the caliper piston seal into the counterbore. 6. Install the bleeder valve and cap to the caliper and tighten the valve securely. 7. Install the front brake caliper to the vehicle. Rear Brake Caliper Overhaul - Rear Removal Procedure 1. Remove the rear brake caliper from the vehicle. Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious: bodily injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. 2. Remove the brake caliper, piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5307 3. Remove the retaining ring that secures the dust boot to the caliper housing. 4. Remove the piston dust boot seal (2) from the seal counterbore in the caliper. Discard the boot seal. 5. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston seal. Important: Do not use abrasives to clean the brake caliper piston. 6. Clean the brake caliper, piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 7. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered air. 8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion. 9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 10. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 11. Inspect the caliper piston for cracks, scoring, and/or damage to the chrome plating. Replace the caliper piston if any of these conditions exist. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5308 1. Lubricate the new piston seal (4) with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 2. Install the lubricated, new piston seal (4) into the caliper bore. 3. Apply a thin coat of Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667) or equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container onto the outer surface area of the caliper piston (3). 4. Install the bottom half of the caliper piston (2) into the caliper bore. 5. Install the new piston dust boot seal (1) over the caliper piston (2). 6. Compress the caliper piston (2) to the bottom of the caliper bore. 7. Fully seat the piston dust boot seal (1) into caliper counterbore. 8. Install the retaining ring that secures the dust boot to the caliper housing. 9. Install the bleeder valve and cap to the caliper and tighten the valve securely. 10. Install the rear brake caliper to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5309 Brake Caliper: Service and Repair Brake Caliper Replacement Front Brake Caliper Replacement - Front Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Remove the front tire and the wheel assembly. 5. Hand tighten 2 wheel lug nuts to retain the rotor to the hub. 6. Install a large C-clamp (2) over the top of the brake caliper and against the back of the outboard brake pad. 7. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor. 8. Remove the C-clamp from the caliper. 9. Remove the brake hose-to-caliper bolt (1) from the caliper. Discard the 2 copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end. 10. Plug the opening in the front brake hose (2) to prevent excessive brake fluid loss and contamination. Important: Note the location of the caliper pin bolts. The leading caliper pin bolt, or top bolt, has a bushing as part of the assembly. The trailing caliper pin bolt, or bottom bolt, is a solid design. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5310 11. Remove the caliper pin bolts (1). Note the location of the caliper pin bolts. The leading caliper pin, or top bolt, has a bushing as part of the assembly. The trailing caliper pin, or bottom bolt, is a solid design. 12. Remove the caliper (2) from the rotor and the caliper bracket (3). 13. Inspect the caliper bolt boots in the caliper bracket for damage. Replace any damaged caliper bolt boots. 14. Inspect the caliper bolts (1) for corrosion or damage. If corrosion or damage is found, use new caliper pin bolts (1) when installing the caliper. Installation Procedure 1. If reusing the brake caliper pin bolts, wipe away any debris and old lubricant with a with a clean shop cloth. 2. Apply lubricant, GM P/N 18047666, or equivalent, to the brake caliper pin bolts. Apply a thin layer to the pin bushing (2) and to the caliper pin bolt shank (3, 4). Ensure that there is not a buildup of excess lubricant at the end of the leading caliper pin (1), in front of the bushing. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5311 3. Install the caliper (2) over the rotor and onto the caliper bracket (3). Notice: Refer to Fastener Notice in Service Precautions. Important: The leading caliper pin, or top bolt, has a bushing as part of the assembly. The trailing caliper pin, or bottom bolt, is a solid design. 4. Install the caliper pin bolts (1). The leading caliper pin bolt, or top bolt, has a bushing as part of the assembly. The trailing caliper pin bolt, or bottom bolt, is a solid design. Ensure that the bolt boots fit securely in the groove of the caliper pin bolts. If the boots are damaged, they must be replaced. ^ Tighten the bolts to 95 Nm (70 ft. lbs.). Important: Install NEW copper brake hose gaskets. 5. Assemble the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose (2). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5312 6. Install the brake hose-to-caliper bolt to the brake caliper. ^ Tighten the bolt to 54 Nm (40 ft. lbs.). 7. Remove the 2 wheel lug nuts retaining the rotor to the hub. 8. Install the front tire and the wheel assembly. 9. Lower the vehicle. 10. Fill the master cylinder to the proper level with clean brake fluid. 11. Bleed the brake system. 12. Inspect the hydraulic brake system for brake fluid leaks. Rear Brake Caliper Replacement - Rear Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Remove the rear tire and the wheel assembly. 5. Hand tighten 2 wheel lug nuts to retain the rotor to the hub. 6. Install a large C-clamp (3) over the top of the brake caliper (2) and against the back of the outboard brake pad. 7. Tighten the C-clamp (3) until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor. 8. Remove the C-clamp (3) from the caliper. 9. Remove the brake hose-to-caliper bolt (1) from the caliper. Discard the 2 copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end. 10. Plug the opening in the rear brake hose (2) to prevent excessive brake fluid loss and contamination. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5313 11. Remove the caliper bolts (1 and 3). 12. Remove the caliper (3) from the rotor (4) and the caliper bracket (1). 13. Inspect the caliper bracket bolt boots on the caliper bracket for the following conditions: ^ Cuts ^ Tears ^ Deterioration Replace any damaged caliper bracket bolt boots. 14. Inspect the caliper bolts (2) for corrosion or damage. If corrosion is found, use new caliper bolts, including bushings, when installing caliper. Installation Procedure 1. Install the caliper (3) over the rotor (4) and the caliper bracket (1). Ensure that the bushings are in place. 2. Lubricate the caliper bolts (1 and 3). Use silicone grease. Do not lubricate the threads. 3. Lubricate the 2 bolt boots (13 and 4) in the caliper bracket (12). Use silicone grease. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5314 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the caliper bolts (1 and 3). Ensure that the bolt boots fit securely in the groove of the caliper bolts. Be sure not to pinch or tear the boots. If the boots are damaged, they must be replaced. ^ Tighten the bolts to 44 Nm (32 ft. lbs.). Important: Install NEW copper gaskets. 5. Assemble the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose (2). 6. Install the brake hose-to-caliper bolt to the brake caliper. ^ Tighten the bolt to 54 Nm (40 ft. lbs.). 7. Remove the 2 wheel lug nuts retaining the rotor to the hub. 8. Install the rear tire and the wheel assembly. 9. Lower the vehicle. 10. Fill the master cylinder to the proper level with clean brake fluid. 11. Bleed the brake system. 12. Inspect the hydraulic brake system for brake fluid leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Specifications Brake Pad: Specifications ^ Replace the disc brake pads when the friction surface is worn to within 0.76 mm (0.030 inch) of the mounting plates. ^ Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake pads to ensure that they are level. Place the disc brake pad friction surfaces together and measure the gap between the surfaces. If more than 0.13 mm (0.005 inch) gap exists midway between the length of the disc brake pads, replace the disc brake pads. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement Brake Pad: Service and Repair Brake Pads Replacement Front Brake Pads Replacement - Front Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Remove the tire and the wheel assembly. 5. Hand tighten two wheel lug nuts in order to retain the rotor to the hub. 6. Compress the front caliper piston. 6.1. Install a large C-clamp (2) over the top of the caliper housing (1) and against the back of the outboard pad. 6.2. Slowly tighten the C-clamp (2) until the piston pushes into the caliper bore enough to slide the caliper (1) off the rotor. 6.3. Remove the C-clamp from the caliper. 7. Remove the lower caliper bolt (1). Notice: Use care to avoid damaging pin boot when rotating caliper. 8. In order to access the pads, rotate the caliper upward and suitably support it. 9. Remove the pads (5) from the caliper bracket (3). 10. Remove the two retainer slides (4) from the caliper bracket (3). 11. Inspect the following parts for cuts, tears, or deterioration. Replace any damaged parts: ^ The disc brake mounting and hardware. ^ The caliper dust boot. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 5320 12. Inspect the caliper bolts (1) for corrosion or damage. If corrosion is found, use new caliper bolts when installing the caliper. Installation Procedure 1. Using a C-clamp, bottom the piston into the caliper bore. Use an old brake pad or wooden block across the face of the piston. Do not damage the piston or the caliper boot. 2. Install the two retainers to the caliper bracket. Important: The wear sensor is on the outside pad. The sensor is positioned at the leading or upward edge of the pad during forward wheel rotation. 3. Install the pads (5) to the caliper anchor bracket (3). Notice: Use care to avoid damaging pin boot when rotating caliper. 4. Remove the support and reposition the caliper (2) back down over the front pads. 5. Lubricate the bolt and the bolt boot. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the lower caliper bolt. ^ Tighten the caliper bolts to 95 Nm (70 ft. lbs.). 7. Remove the two wheel lug nuts retaining the rotor to the hub. 8. Install the tire and the wheel assembly. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10 and 11 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 13. Fill the brake master cylinder reservoir to the proper level. 14. Burnish the pads and rotors. Rear Brake Pads Replacement - Rear Removal Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 5321 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Remove the rear tire and the wheel assembly. 5. Install a hand tightened lug nut to retain the rotor to the hub. 6. Compress the caliper piston enough for clearance. Use a C-clamp (3). 7. Remove the upper caliper bolt (2). Notice: Use care to avoid damaging pin boot when rotating caliper. 8. Pivot the caliper down in order to access the pads. It is not necessary to remove the caliper. 9. Remove the brake pads (2) from the caliper bracket. 10. Remove the 2 pad clips (1) from the caliper bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 5322 11. Inspect the caliper mounting hardware for the following conditions: ^ Cuts ^ Tears ^ Deterioration Replace any hardware if damage exists. 12. Inspect the caliper dust boot for the following conditions: ^ Cuts ^ Tears ^ Deterioration Replace the caliper dust boot if damage exists. 13. Inspect the caliper bolts for corrosion or damage. If corrosion exists, use new caliper bolts when installing the caliper. Installation Procedure 1. Bottom the piston into the caliper bore. Use a C-clamp before installing new brake pads in order to compress the piston. Use an old brake pad or wooden block across the face of the piston to avoid damage to the piston or the caliper boot. 2. Install the 2 retainers (1) to the caliper bracket. Important: The wear sensor is on the outside pad. The sensor is positioned at the trailing or downward edge of the pad during forward wheel rotation. 3. Install the pads (2) to the caliper bracket. Notice: Use care to avoid damaging pin boot when rotating caliper. 4. Swing the caliper (3) upward in position around the pads. 5. Lubricate the bolt and the bolt boot. Use silicone grease. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the upper caliper bolt (2). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 5323 ^ Tighten the caliper bolt to 44 Nm (32 ft. lbs.). 7. Remove the wheel lug nut retaining the rotor to the hub. 8. Install the rear tire and the wheel assembly. Align the previous marks on the wheel, hub and bearing. 9. Lower the vehicle. 10. With the engine OFF, gradually apply the brake pedal to approximately 213 of its travel distance. 11. Slowly release the brake pedal. 12. Wait 15 seconds, then repeat steps 10 and 11 until a firm brake pedal is obtained. This will properly seat the brake caliper pistons and brake pads. 13. Fill the brake master cylinder reservoir to the proper level. 14. Burnish the pads and rotors. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information > Service and Repair > Brake Pads Replacement > Page 5324 Brake Pad: Service and Repair Burnishing Pads and Rotors Burnishing Pads and Rotors Caution: Refer to Road Test Caution in Service Precautions. Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly prepared after service has been performed on the disc brake system. This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or whenever the disc brake pads have been replaced. 1. Select a smooth road with little or no traffic. 2. Accelerate the vehicle to 48 km/h (30 mph). Important: Use care to avoid overheating the brakes) while performing this step. 3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes to lock. 4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods between stops, in order to properly burnish the brake pads and rotors. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures Technical Service Bulletin # 00-05-22-002L Date: 090326 Brakes- Disc Brake Warranty Service And Procedures INFORMATION Bulletin No.: 00-05-22-002L Date: March 26, 2009 Subject: Disc Brake Warranty Service and Procedures Models: 1999-2010 GM Passenger Cars and Light Duty Trucks 2003-2010 HUMMER H2 2006-2010 HUMMER H3 1999-2004 Isuzu Light Duty Trucks (Canada Only) 2005-2009 Saab 9-7X (Canada Only) 1999-2010 Saturn Vehicles (Canada Only) EXCLUDING 2009-2010 Chevrolet Corvette ZR1 Supercede: This bulletin is being revised to inform you that due to improvements in vehicle brake corner and wheel design, assembly plant build processes and dealership required tools like the On-Car Lathe, measuring for Lateral Run Out (LRO) is no longer a required step when performing base brake service. Due to this change, you are no longer required to enter the LRO measurement on the repair order or in the warranty system failure code section. The bulletin information below and the base brake labor operations have been updated accordingly. Due to this change it is more important than ever to properly maintain your brake lathe (per the Brake Lathe Calibration Procedure in this bulletin). Please discard Corporate Bulletin Number 00-05-22-002K (Section 05 Brakes). For your convenience, this bulletin updates and centralizes all GM's Standard Brake Service Procedures and Policy Guidelines for brake rotor and brake pad service and wear. For additional information, the Service Technical College lists a complete index of available Brake courses. This information can be accessed at www.gmtraining.com > resources > training materials > brakes courseware index. In Canada, refer to Service Know How course 55040.00V and Hydraulic Brake Certification program 15003.16H. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM BRAKE SERVICE. The following four (4) key steps are a summary of this bulletin and are REQUIRED in completing a successful brake service. 1. Measure and Document Pre-Service Rotor Thickness* (REQUIRED on Repair Order) determine rotor clean-up/refinish/replace 2. Properly clean ALL brake corner mating surfaces - hub, rotor and wheel 3. Properly clean-up/refinish rotor, measure and document post-service rotor thickness (REQUIRED on Repair Order) Important If it is determined the rotor needs to be refinished, verify lathe equipment is properly calibrated. 4. Properly reassemble the brake corner using proper torque tools, torque specification and torque sequence - wheel lug nuts. * The bulletin refers to Minimum Thickness specification as the minimum allowable thickness after refinish. Always refer to SI to verify the spec stamped on the rotor is the minimum thickness spec after refinish and not the discard spec. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5329 Bulletin Format ***REPAIR ORDER REQUIRED DOCUMENTATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5330 Important When using any one of the brake labor operations listed in this bulletin (except for H9709 - Brake Burnish), the following two rotor measurements (1. Original Rotor Thickness, 2. Refinished Rotor Thickness are required and MUST be written/documented on the repair order, or for your convenience, complete the form (GM Brake Service Repair Order Documentation for Required Measurements) shown above and attach it to the repair order. If the Warranty Parts Center generates a request, this Documentation/Form must be attached to the repair order that is sent back. Important Documentation of brake lathe maintenance and calibration as recommended by the lathe manufacturer must be available for review upon request. Repair Order Documentation - Rotor Original And Refinished Thickness - REQUIRED When resurfacing a brake rotor or drum, the ORIGINAL thickness (measured thickness before refinish) and REFINISHED thickness (measured thickness after refinish) MUST be written/documented on the repair order hard copy for each rotor serviced. If a rotor replacement is necessary, only the original thickness measurement needs to be recorded. Repair Order Documentation - Explanation of Part Replacement - REQUIRED If replacement of a brake component is necessary, proper documentation on the repair order is required. See the following examples: ^ Brake rotor replacement - Customer comment was brake pulsation. Rotor was refinished on a prior brake service. After rotor measurement, it was determined that refinishing the rotor again would take it under the Minimum Thickness specification. ^ Brake pad replacement - Customer comment was brake squeak noise. On inspection, found pads contaminated by fluid leak at caliper. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5331 TOOL INFORMATION CORRECTION PLATE PART INFORMATION Refer to TSB 01-05-23-001 for the Brake Align(R) application chart. For vehicles repaired under warranty, Brake Align(R) Run-Out Correction Plates should be submitted in the Net Amount at cost plus 40%. Brake Align(R) Run-Out Correction Plates are available through the following suppliers: - Dealer Equipment and Services - Brake Align(R) LLC (U.S. Dealers Only) * We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items, which may be available from other sources. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5332 WARRANTY INFORMATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5333 WORKSHEET - BRAKE LATHE CALIBRATION Important Brake lathe calibration should be performed and recorded monthly or if you are consistently measuring high LRO after rotor refinishing. Disclaimer GM Brake Service Procedure GM BRAKE SERVICE PROCEDURE 1. Remove the wheel and caliper. 2. Measure rotor thickness. In order to determine if the rotor can be refinished, do the following steps: Important Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5334 If performing routine Brake Service for worn pads only, and the rotors are not damaged and measure within specification - DO NOT REFINISH ROTORS. 1. Remove the rotor(s). 2. Measure the rotor for original thickness using a brake micrometer. Multiple measure points should be taken and the lowest measurement should be recorded. 3. Reference the Minimum Thickness specification stamped on the backside of the rotor or SI for Minimum Thickness specification/other. In most cases, the rotor should be refinished unless the measurement taken makes it obvious that refinishing the rotor would take the measurement under the Minimum Thickness specification (then replacement is necessary). DO NOT use any other manufacturers rotor specifications. 3. ***Record the lowest ORIGINAL rotor thickness measurement on the repair order hard copy as noted in the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 4. Clean all of the mating surfaces between the hub, the rotor and the wheel using the J 42450A Wheel Hub Cleaning Kit and J 41013 - Whiz Wheel(R). If rotors are not to be refinished - Go To Step 8. Important Cleaning all mating surfaces and making them free of corrosion, burrs and other debris (which includes removal of Hubless rotors) is critical and MUST be performed whether using an On-Car or Bench Lathe Refinish Procedure. 5. Be sure to follow the appropriate refinishing procedure listed below for the type of lathe you are using. Important Only replace the rotors if they do not meet the Minimum Thickness specification. Important DO NOT REFINISH NEW ROTORS. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important Prior to making the cut, install the recommended clip-on style disc silencer supplied with the lathe. Use of this silencer is critical to prevent chatter from occurring during the cut. Bench Type Lathe 1. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. 2. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information, see the "Brake Lathe Calibration Procedure (Bench-Type)" section in this bulletin. 3. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn 4. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 5. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 6. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 7. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. On-Car Type Lathe 1. Reinstall the rotor(s). Important Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5335 When using the On-Car lathe on vehicles equipped with limited slip (or posi-trac) rear system, it is critical that the rear drive shaft is disconnected/disengaged prior to operation of the On-Car lathe. Remember to mark and re-index the drive shaft correctly on re-assembly to prevent creating driveline vibration. Whenever the lathe drive motor is being switched on, the operator MUST keep their body out of the wheel well area until the machine has reached its normal operating RPM. 2. Refinish the existing rotor on an approved, well-maintained lathe to guarantee smooth, flat and parallel surfaces. Important When raising the vehicle on the lift, be sure to have it at a good working height (waist high is average) to accommodate mounting the On-Car lathe. Optimally, the center piston on the lathe trolley will be mid-travel. If the lathe trolley center piston is completely compressed (bottoming out) or inversely fully extended and hanging off the vehicle hub, this could affect the calibration time of the lathe. 3. Select the correct adapter for the vehicle you're working on and mount it to the hub with the vehicle lug nuts. Hand tighten 34-41 Nm (25-30 lb ft) the nuts using equal torque. DO NOT use impact wrenches, excessive torque will damage the adapter. Important Ensure the adapter sits flush on the rotor hat surface. Be sure to remove any rust, rotor retaining clips, etc. that may preclude the adapter from sitting flat on the mounting surface. 4. Connect the lathe to the adapter, turn on the lathe and activate the computer to compensate for run-out in the hub. 5. Once the computer indicates the compensation process was successful, on the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 6. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 7. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 8. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 9. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. 10. Dismount the lathe, but leave the lathe adapter attached to the vehicle. 6. Once the rotor has been properly machined, wash the rotor with soap and water (use a mild dish washing soap) or wipe it clean with GM approved brake cleaner, P/N 88862650 (Canadian P/N 88901247). Important Thoroughly cleaning the rotor will prevent the possible transfer of finite metal dust left as a by-product of machining to the pad material during the seating process, thus reducing the opportunity for squeaks or other noises to occur. 7. ***Record the REFINISHED rotor thickness measurement on the repair order hard copy. Refer to the "Repair Order Documentation - Rotor Refinish" section of this bulletin. 8. Setting up to measure for Lateral Run Out (LRO): Important Measuring for Lateral Run Out (LRO) (steps 8 - 15) is no longer required however, these steps are being left in the overall procedure as a good check to be performed in the case of a repeat pulsation complaint. If you are not checking for LRO, go to step 16. Bench-Type Lathe 1. Ensure that the mating surfaces of the rotor hat section and the hub mating surface are clean and free of debris. 2. Mount the new, original or refinished rotor onto the vehicle hub. Important Always hold the rotor on the bottom half so any debris that may be dislodged from the vents will fall out instead of falling into the mounting area. Any movement or jarring from the rotor falling over on the studs can release rust from the vents on the rotor. 3. Tilt the top of the rotor in towards the vehicle so you can see the studs and ease the rotor onto the studs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5336 4. Slide the rotor all the way to the hub and hold it in place until you have placed one of the conical washers (with the tapered hole side facing out) and run the first lug nut up tight by hand so the rotor doesn't move when you release it. 5. Place the conical washers on the rest of the studs (with the tapered hole side facing out), start and snug the lug nuts by hand. 6. Using the one half inch drive impact wrench and a torque stick (J 39544) or equivalent, start with the lug nut opposite of the one you first tightened by hand and tighten the lug nuts using a star pattern until they touch the hub but do not completely torque. Then again, starting with the first lug nut you tightened by hand, tighten all the lug nuts in a star pattern to the specific vehicle torque specification. 7. DO NOT reinstall the caliper or the wheel at this time. On-Car Type Lathe 1. Leave the On-Car adapter on the wheel. 2. Proceed to Step 9. 9. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor outboard friction surface approximately 6.35 mm (0.25 in) from the rotor's outer edge. The stylus should be perpendicular to the friction surface of the rotor. Important Make sure the dial indicator needle tip is screwed tight, a loose tip could cause false readings. 10. Measure for LRO. Follow the procedure below to determine if the LRO is within specification (0.050 mm (0.002 in) or LESS). 1. Rotate the rotor and locate the point on the rotor where the lowest dial indicator reading is indicated and set the dial indicator to zero. 2. Rotate the rotor from the low point and locate the point with the highest dial indicator reading (rotor "high spot"). Note the amount and mark the location of the "high spot" on the rotor and mark the closest wheel stud relative to this location. If the high point falls between two studs, mark both studs. In instances where the vehicle has "capped lug nuts" you should mark the hub. 11. If the Lateral Run Out (LRO) measurement is 0.050 mm (0.002 in) or LESS, no correction is necessary. Go to Step 15 if this is the first rotor completed. Go to Step 16 if this is the second rotor completed. If the LRO is GREATER than 0.050 mm (0.002 in), go to Step 12. 12. If the LRO measurement is greater than 0.050 mm (0.002 in), use the following procedure to correct for LRO: Important If the LRO measurement is over 0.279 mm (0.011 in), determine the source or cause of the LRO and correct it (i.e. verify drive axle nut torque specification, refinished rotor is source of LRO due to a lathe qualification issue - see "Brake Lathe Calibration Procedure"). Hubless Rotor 1. Remove the rotor and using the Brake Align(R) application chart (found in TSB 01-05-23-001B), choose the correct plate to bring the rotor LRO to 0.050 mm (0.002 in) or less. The plates come in 0.0762 mm (0.003 in), 0.1524 mm (0.006 in) and 0.2286 (0.009 in) compensation. For more information on proper plate selection, see the instruction video/DVD included in the "Brake Align(R)" kit or TSB 01-05-23-001B. 2. Align the V-notch of the selected Brake Align(R) correction plate to the marked wheel stud ("high spot") or between the two points marked (if the "high spot" is between two wheel studs). Important IF Brake Align(R) Correction Plates are not available for the vehicle being serviced, refer to SI Document - Brake Rotor Assembled Lateral Runout Correction for correcting LRO. Important Per Brake Align(R) manufacturer, NEVER attempt to stack two or more Correction Plates together on one hub. NEVER attempt to reuse a previously installed Correction Plate. 3. Reinstall the rotor using the same method and precautions as the first time - found in Step 8. Make sure to index the rotor correctly to the marks made in step 10, otherwise LRO will be comprised. Hubbed / Captured / Trapped Rotor 1. Measure the rotor thickness. 2. Refinish or replace the rotor (see Service Information for further details). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5337 13. Use a Dial Indicator to measure the rotor to verify the LRO is within specification. 14. If using, BENCH LATHE - DO NOT remove conical washers and lug nuts at this time. ON-CAR LATHE - You must remove adapter and install conical washers and lug nuts to retain rotor position. Important For Hubless rotor design, while removing the adapter, you must hold the rotor tight to the hub and install the top conical washer and lug nut first to ensure no debris falls between the surface while removing the adapter. Then, install the remaining conical washers and lug nuts. Otherwise, LRO will be comprised. 15. Perform Steps 1 through 7 on the opposite side of the vehicle (steps 1-12, if performing LRO). 16. Reinstall the rotors on both sides of the vehicle and perform the following steps: 1. Reinstall the calipers and pads. 2. Pump the brakes to pressurize the calipers. 3. Remove the lug nuts/conical washers. 4. Install and properly torque the wheels. Important It is critical to follow the star pattern wheel torque procedure and use the proper tools (torque stick or torque wrench) as referenced in SI. 17. Road test the vehicle to verify the repairs. Brake Lathe Calibration Procedure BRAKE LATHE CALIBRATION PROCEDURE Calibration of the brake lathe should be performed and recorded monthly or whenever post-service brake rotor LRO measurements are consistently reading above specification. BENCH-TYPE LATHE Use the following procedure to calibrate a Bench-type brake lathe: 1. After refinishing a rotor, loosen the arbor nut and while holding the inside bell clamp to keep it from rotating, rotate the rotor 180 degrees. 2. Retighten the arbor nut and set the dial indicator on the rotor using the same instructions as checking the run out on the vehicle. 3. Rotate the arbor and read the runout. 4. Divide the reading by two and this will give you the amount of runout the lathe is cutting into the rotor. Important If there is any runout, you will need to machine the inside bell clamp in place on the lathe (this procedure is for a Bench type lathe ONLY, DO NOT machine inside the bell clamp on an On-Car type lathe). Machining the Inside Bell Clamp (Bench Type Lathe Only) Any nicks or burrs on the shoulder of the arbor must be removed. An 80-grit stone can be used to accomplish this. Spray WD-40(R) on the shoulder and with the lathe running, hold the stone flat against the shoulder surface using slight pressure. When the burrs are gone, clean the surface. Burrs must also be removed from the hub of the inside bell clamp. This can be accomplished with the stone and WD-40(R). Keep the stone flat on the hub while removing the burrs. After removing the burrs, clean the hub. Place the bell clamp on the arbor of the lathe and use the small radius adapters first and then spacers to allow you to tighten the arbor nut to secure the bell clamp to the lathe. Position the tool bit in the left hand of the rotor truer so you can machine the face of the bell clamp. Machine the face of the bell clamp taking just enough off of it to cut the full face of the clamp the full 360 degrees. Before you loosen the arbor nut, match mark the hub of the bell clamp to the arbor and line up these marks before machining a rotor. A magic marker can be used to make the match marks. Machine a rotor and recheck the calibration. Repeat this procedure on all Inside Bell Clamps used. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5338 Important If runout is still present, contact the brake lathe supplier. ON-CAR TYPE LATHE Use the following procedure to calibrate an On-Car brake lathe: 1. Connect the lathe to a vehicle using the appropriate adapter. 2. Attach a vise-grip dial indicator to a fixed point in the wheel well and bring the dial indicator to a flat surface on the cutting head. 3. Turn on the lathe and press the "start" button so the lathe begins to compensate. 4. Once compensation is complete, note the runout as measured by the dial indicator. Measured runout at this point is overstated given that it is outside the rotor diameter. 5. If runout is in excess of 0.1016 mm (0.004 in) (0.050 mm (0.002 in) as measured within the rotor diameter), calibration must be tightened. Follow manufacturer's instructions for tightening the calibration of the lathe. This information is found in the manual supplied with the lathe. Important If the machine is taking a long time to compensate during normal use, prior to checking the lathe calibration, it is recommended that the machine be disconnected from the adapter and the adapter (still connected to the vehicle) is rotated 180 degrees and the machine reattached. This will accomplish two things: - It will re-verify the machine is properly attached to the adapter. - It will change the location of the runout (phase) relative to the machine and thus possibly allow for quick compensation as a result of the position change. The following information has been added as a reference to ensure your Pro-Cut PFM lathe provides a consistent smooth surface finish over long term usage. Cutting Tips / Depth of Cut / Tip Life The cutting tips must be right side up. Reference marks always face up. The cutting tips may not have chips or dings in the surface of the points. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. When cleaning or rotating the cutting bits, make sure that the seat area for the tip on the tool is free and clear of debris. Cutting Head On each brake job, the technician must center the cutting head for that particular vehicle using one of the mounting bolt holes on the slide plate. Once the head is centered, it is vital that the technician use one hand to push the head firmly and squarely back into the dovetail on the slide plate while using the other hand to tighten the Allen-Hex bolt that secures the head. Failure to do this could result in chatter occurring during the cut. Tool Holder Plate (Cutting Head) The tool holder plate is the plate that the cutting arms are attached to. It can bend or break if a technician accidently runs the cutting arms into the hub of the rotor while the rotor is turning. (Cuts of more than 0.508 mm (0.020 in) can also bend this plate). Once bent, the lathe will most likely not cut properly until the tool holder plate is replaced. In order to verify the condition of the tool holder plate on a machine that will not cut right, remove the mounting bolt and remove the cutting head from the slide plate. With the cutting head titled at an angle, lay the long edge of the tool holder plate down on the flat part of the slide plate. If any gap can be seen between the edge and the slide plate, the tool holder plate is bent and the source of vibration. Also check to ensure that the cutting arms are lying flat on the upper side of the tool holder plate. If the mounting arm post is bent, it will show itself by having the back of the cutting arm lifting off the surface of the tool holder. Gib Adjustment / Loose Gib As wear occurs between the slide plate and the box it rides on, you must take up the slack. You do this by way of a moveable wedge, which we call the gib. Your lathe manual details adjustment process, which you should perform when required after monthly checks or whenever surface finish is inconsistent. Brake Pulsation BRAKE PULSATION Brake pulsation is caused by brake rotor thickness variation. Brake rotor thickness variation causes the piston in the brake caliper, when applied, to "pump" in and out of the caliper housing. The "pumping" effect is transmitted hydraulically to the brake pedal. Brake pulsation concerns may result from two basic conditions: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5339 1. Thickness Variation Pulsation is Caused by Lateral Run Out (LRO). LRO on a brake corner assembly is virtually undetectable unless measured (with a dial indicator after the brake service) and will not be detected as brake pulsation during an after brake service test drive. If the brake corner is assembled with excessive LRO (greater than 0.050 mm (0.002 in), thickness variation will develop on the brake rotor over time and miles. Excessive LRO will cause the brake pads to wear the brake rotors unevenly, which causes rotor thickness variation. Pulsation that is the result of excessive Lateral Run Out usually develops in 4,800-16,000 km (3,000-10,000 mi). The more excessive the LRO, the faster the pulsation will develop. LRO can also be induced when uneven torque is applied to wheel nuts (lug nuts). Improper wheel tightening after tire rotation, spare tire usage, brake inspection, etc. can be the cause of brake pulsation. Again, it usually takes 4,800-16,000 km (3,000-10,000 mi) AFTER the service event for the condition to develop. The customer does not usually make the connection between the service event and the awareness of the pulsation. The proper usage of torque wrenches and/or torque sticks (torque limiting sockets) will greatly reduce or eliminate the pulsation conditions after wheel service events. The improper use of impact wrenches on wheel nuts greatly increases the likelihood of pulsation after wheel service. The following are examples of pulsation conditions and reimbursement recommendations: - If the customer noticed the condition between 4,800-16,000 km (3,000-10,000 mi) and it gradually got worse, normally the repair would be covered. The customer may tolerate the condition until it becomes very apparent. - If a GM dealer performed a prior brake service, consider paying for the repair and then strongly reinforce proper brake lathe maintenance. - If the customer had the brake service done outside of a GM dealership, normally GM would not offer any assistance. - If a customer indicated they had wheel service, ask who performed the service. Then; - If a GM dealer performed the service, consider paying for the repair and then strongly reinforce the use of torque sticks at the dealer. Two common size torque sticks cover 90% of all GM products. Each technician needs to use torque sticks properly every time the wheel nuts are tightened. - If the customer had the wheel service done outside of a GM dealership, normally GM would not offer any assistance. 2. Thickness Variation Pulsation Caused by Brake Rotor Corrosion - Rotor corrosion is another form of thickness variation, which can cause a pulsation concern and can be addressed as follows: - Cosmetic Corrosion: In most instances rotor corrosion is cosmetic and refinishing the rotor is unnecessary. - Corrosion - Pulsation Caused by Thickness Variation (Lot Rot / Low Miles - 0-321 km (0-200 mi): At times more extensive corrosion can cause pulsation due to thickness variation. This usually happens when the vehicle is parked for long periods of time in humid type conditions and the braking surface area under the pads corrodes at a different rate compared to the rest of the braking surface area. Cleaning up of braking surfaces (burnishing) can be accomplished by 10 - 15 moderate stops from 56- 64 km/h (35 - 40 mph) with cooling time between stops. If multiple moderate braking stops do not correct this condition, follow the "Brake Rotor Clean-Up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (without rotor flaking / higher mileage 3,200-8,000 km (2,000-5,000 mi): In some cases, more extensive corrosion that is not cleaned up by the brake pad over time and miles can cause the same type of pulsation complaint due to thickness variation. In these cases, the rotor surface is usually darker instead of shiny and a brake pad foot print can be seen against the darker surface. This darker surface is usually due to build-up, on the rotor material surface, caused by a combination of corrosion, pad material and heat. To correct this condition, follow the "Brake Rotor Clean-up Procedure" below. - Corrosion - Pulsation Caused by Thickness Variation (with rotor flaking / higher mileage - 8,000 + km (5,000 + miles) : At times, more extensive corrosion over time and miles can cause pulsation due to thickness variation (flaking). This flaking is usually a build up, mostly on the rotor material surface, caused by a combination of corrosion, pad material and heat. When rotor measurements are taken, the low areas are usually close to the original rotor thickness (new rotor) measurement and the high areas usually measure more than the original rotor thickness (new rotor) measurement (depending on mileage and normal wear). To correct this condition, follow the "Brake Rotor Clean-up Procedure" described below. Important In some flaking instances, cleaning-up this type of corrosion may require more rotor material to be removed then desired. Customer consideration should be taken in these situations and handled on a case by case basis, depending on the amount/percentage of rotor life remaining and the vehicle's warranty time and miles. Brake Rotor Clean-Up Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5340 BRAKE ROTOR CLEAN-UP PROCEDURE Clean-up the rotors on an approved, well-maintained brake lathe to guarantee smooth, flat and parallel surfaces. Check for clean and true lathe adapters and make sure the arbor shoulder is clean and free of debris or burrs. For more information see the "Brake Lathe Calibration Procedure" section in this bulletin. 1. On the outboard area of the rotor, position the cutting tools one eighth of an inch into the brake pad area of the rotor. Feed the cutting tools into the rotor until they cut the rotor to new metal, a full 360 degrees. Zero each dial and back off a full turn. 2. Move the cutting bits to the middle of the rotor and do the same procedure. If zero is passed during the process, reset zero. Back off a full turn. 3. Position the cutting bits one eighth of an inch inside the inboard (closest to the hub) edge of the brake pad contact area. Do the same procedure. If zero is passed during the process, reset zero. 4. Back off a full turn and position the cutting bits all the way inboard in preparation to refinish the full rotor surface. Advance both tool cutters to the zero setting plus just enough to clean up the entire rotor surface. 5. After completing the refinish, sand both sides of the rotor for approximately one minute per side using a sanding block and 130-150 grit sandpaper to obtain a non-directional finish. Important Only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. Important In many of these instances, such a minimal amount of material is removed from the rotor that customer satisfaction is not a concern for future brake services. This procedure is intended to "Clean-up" the rotor surface and should be conveyed to the customer as such - not as "cut", "refinish" or "machine", which tends to be terms understood as a substantial reduction of rotor material/life. If the brake lathe equipment being used is not capable of removing minor amounts of material while holding tolerances, further lathe maintenance, repair, updates or equipment replacement may be necessary. Brake Noise BRAKE NOISE Some brake noise is normal and differences in loading, type of driving, or driving style can make a difference in brake wear on the same make and model. Depending on weather conditions, driving patterns and the local environment, brake noise may become more or less apparent. Verify all metal-to-metal contact areas between pads, pad guides, caliper and knuckles are clean and lubricated with a thin layer of high temperature silicone grease. Brake noise is caused by a "slip-stick" vibration of brake components. While intermittent brake noise may be normal, performing 3 to 4 aggressive stops may temporarily reduce or eliminate most brake squeal. If the noise persists and is consistently occurring, a brake dampening compound may be applied to the back of each pad. This allows parts to slide freely and not vibrate when moving relative to each other. Use Silicone Brake Lubricant, ACDelco P/N 88862181 (Canadian P/N 88862496) or equivalent. The following noises are characteristics of all braking systems and are unavoidable. They may not indicate improper operation of the brake system. Squeak/Squeal Noise: - Occurs with front semi-metallic brake pads at medium speeds when light to medium pressure is applied to the brake pedal. - Occasionally a noise may occur on rear brakes during the first few stops or with cold brakes and/or high humidity. Grinding Noise: - Common to rear brakes and some front disc brakes during initial stops after the vehicle has been parked overnight. - Caused by corrosion on the metal surfaces during vehicle non-use. Usually disappears after a few stops. Groan Noise: A groan type noise may be heard when stopping quickly or moving forward slowly from a complete stop. This is normal. On vehicles equipped with ABS, a groan or moan type noise during hard braking applications or loose gravel, wet or icy road conditions is a normal function of the ABS activation. Key Points - Frequently Asked Questions KEY POINTS - FREQUENTLY ASKED QUESTIONS - Q: How do on-car lathes react to Axle Float? Does the play affect the machining of the rotor, either surface finish or LRO? Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5341 A: Because the Pro-Cut on-car lathe adjusts in a live mode while spinning the hub/rotor, the dynamics of a floating axle are effectively eliminated. Once the lathe is compensated, there is no difference in the cutting/surface finish and LRO are just the same as with a non-floating axle. - Q: Which lathe is essential for performing brake work, the bench or on-car? A: Dealers must have a well maintained bench lathe and well maintained on-car lathe. These lathes need to be calibrated on a monthly basis. BOTH lathes are essential to providing quality brake service. - Q: What is the expected tip life for an on-car lathe? A: The geometry and composition of the Pro-Cut tips are designed for "single pass" cutting. When using the Pro-Cut the cutting depth should be set to take all material needed to get below rust grooves, eliminate all run-out and resurface the entire disc in a single pass. Cuts of 0.1016-0.381 mm (0.004-0.015 in) will provide the best surface finish and the optimal tip life. No "skim cut" or "finish cut" is needed. Failure to follow this procedure will shorten tip life. The Pro-cut tips will last between 7-12 cuts per corner. With three usable corners, a pair of tips is good for at least 21 cuts. - Q: Why does GM recommend the use of single pass (referred to as "positive rake") bench and on-car brake lathes? A: GM Service and GM Brake Engineering have performed competitive evaluations on a significant number of bench and on-car brake lathes. These tests measured critical performance characteristics such as flatness, surface finish and the ability of the lathe to repeat accuracy over many uses. In each test, single pass lathe designs out performed the competitors. Single pass brake lathes are more productive requiring less time to perform the same procedure. - Q: Is it okay to leave the caliper/pads installed while cutting rotors using an on-car lathe? A: On-car lathes should never be used with the pads and calipers installed on the vehicle. The debris from cutting the rotors can contaminate the brake pads/calipers which can lead to other brake concerns and comebacks. - Q: What information needs to be documented on the Repair Order? A: Any claim that is submitted using the labor operations in this bulletin, must have the Original Rotor Thickness and Refinish Rotor Thickness (if refinished) documented on the repair order. For more information, refer to the "Repair Order Required Documentation" section of this bulletin. All Warranty Repair Orders paid by GM, are subject to review for compliance and may be debited where the repair does not comply with this procedure. Brake Warranty BRAKE WARRANTY Brake Rotors: - Brake rotor warranty is covered under the terms of the GM New Vehicle Limited Warranty. Reference the vehicle's warranty guide for verification. - Rotors should not be refinished or replaced during normal/routine pad replacement. - Rotors should not be refinished or replaced and is ineffective in correcting brake squeal type noises and/or premature lining wear out. - Rotors should not be refinished or replaced for cosmetic corrosion. Clean up of braking surfaces can be accomplished by 10-15 moderate stops from 56-64 km/h (35-40 mph) with cooling time between stops. - Rotors should not be refinished or replaced for rotor discoloration/hard spots. - Rotors should be refinished NOT replaced for Customer Pulsation concerns. This condition is a result of rotor thickness variation, usually caused by LRO (wear induced over time and miles) or corrosion (Lot Rot). - When rotor refinishing, only remove the necessary amount of material from each side of the rotor and note that equal amounts of material do not have to be removed from both sides on any brake system using a floating caliper. - Rotors should be refinished for severe scoring - depth in excess of 1.5 mm (0.060 in). Important If the scoring depth is more than 1.5 mm (0.060 in) after the rotor is refinished, it should be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5342 - It is not necessary to replace rotors in pairs. Rotors may be replaced individually. However, caution should be exercised, as a variance in surface finish may cause a brake pull condition. - New rotors should not be refinished before installation. Original equipment rotor surfaces are ground to ensure smooth finish and parallelism between mounting and friction surfaces. If a new rotor has more than 0.050 mm (0.002 in) Lateral Run Out (LRO) when properly mounted on the hub, correct it using one of the following methods: 1. For hubless rotor designs, use the correction plate procedure found in the "GM Brake Service Procedure for Hubless Rotors" outlined in this bulletin. 2. For hubbed/trapped/captured rotor designs, refinish the rotor using an On-Car lathe and the procedure outlined in this bulletin. - Never reuse rotors that measure under the Minimum Thickness specification. In this instance, the rotor should be replaced. Important If the Minimum Thickness specification is not visible on the rotor, reference Service Information (SI) for the specific vehicle application. DO NOT use any other manufacturers rotor specifications. Brake Pads: Important When determining the warranty coverage (as an example) - if all four front or four rear brake pads are excessively worn evenly, that would NOT be covered under warranty since this type of wear is most likely due to driving habits or trailering. However, if the brake pads are excessively worn un-evenly, side-to-side or same side/inner-to-outer pads, then consideration should be given to cover this under warranty since this type of wear is most likely due to poor operation of other braking components. - Consideration should be given for covering brake pads up to 39,000 km (24,000 mi) (excluding owner abuse, excessive trailering, or the situations that would not be considered normal use). - Installation of new rotors does not require pad replacement. Do not replace pads unless their condition requires it - excessively worn, damage or contaminated. Brake Wear: Several factors impact brake lining wear and should be taken into account when reviewing related issues: - heavy loads / high temperatures / towing / mountainous driving / city driving / aggressive driving / driver braking characteristics (left foot or two feet) The following are conditions that may extend brake lining wear: - light loads / highway driving / conservative driving / level terrain Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5343 Brake Rotor/Disc: Technical Service Bulletins Brakes - Rotor Lateral Runout Correction Information Bulletin No.: 01-05-23-001B Date: January 31, 2008 INFORMATION Subject: Brake Align(R) System for Brake Rotor Lateral Runout Correction Models: 2008 and Prior Passenger Cars Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 01-05-23-001A (Section 05 - Brakes). This bulletin is being issued to update General Motors position on correcting brake rotor lateral runout (Refer to Corporate Bulletin Number 00-05-22-002B for additional brake rotor service procedures). Certain conditions may apply to individual vehicles regarding specific repairs. Refer to those specific repairs in applicable service bulletins. Make sure other possible sources of brake pulsation, such as ABS pedal feedback, have been addressed before checking rotor runout. Anytime a new or refinished rotor is installed on a vehicle, the rotor must have .050 mm (.002 in) or less of lateral runout. This specification is important to prevent comebacks for brake pulsation. Until now, the only acceptable methods to correct brake rotor runout were to index or replace the rotor or to refinish the rotor using an on-vehicle brake lathe. GM has approved a new technology for the correction of lateral runout on new or refinished rotors. This new method is called Brake align(R)*. It will allow the technician to meet the .050 mm (.002 in) or less requirement for lateral runout by installing a specially selected, tapered correction plate between the rotor and the hub. The Brake Align(R) Correction system does NOT require the use of an on-vehicle brake lathe to correct for lateral runout. *We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources. The Brake Align(R) Starter Kit will include an ample supply of Correction Plates, in various correction sizes, that will cover most current GM passenger car applications. It will also include a Brake Align(R) tool kit containing a dial indicator and retaining washers along with other useful tools. Service Procedure Follow all the procedures referred to in Corporate Bulletin Number 00-05-22-002B. Dealers who have purchased the Brake Align(R) Starter Kit may use the following simplified runout correction procedure: The existing rotors must first be machined on an approved, well-maintained bench lathe to guarantee smooth, flat, and parallel surfaces. Should the rotors require replacement, please note that it is not necessary to machine new rotors. Make sure all the mating surfaces of the rotor and the hub are clean, using the J 42450-A wheel Hub Cleaning Kit. Mount the new or refinished rotor onto the vehicle hub using the retaining washers provided in the kit. Do not reinstall the caliper or wheel at this time. Tighten all the wheel nuts to the proper specification, using J 39544 Torque Socket or the equivalent. Fasten the dial indicator to the steering knuckle so that the indicator needle contacts the rotor friction surface approximately 12.7 mm (1/2 in) from the rotors outer edge. Rotate the rotor and observe the total lateral runout. Index the rotor on the hub to achieve the lowest amount of lateral runout. This will require removal and reassembly of the rotor until the lowest total lateral runout reading is obtained. If this reading is .050 mm (.002 in) or less, the assembled rotor is within specification. The brake system may be reassembled. If total lateral runout is greater than .050 mm (.002 in), proceed with determining the correct Brake Align(R) Correction as follows: Rotate the rotor to locate the lowest dial indicator reading and set the dial to zero. Rotate the rotor to determine and locate the highest amount of lateral runout. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5344 Note the AMOUNT and LOCATION of the "high spot" on the rotor and mark the closest wheel stud relative to this location. Remove the rotor. Select the appropriate Brake Align(R) Runout Correction Plate for this vehicle using the Application Chart. Make sure the selection corrects the amount of runout that was diagnosed. Never attempt to stack two or more Correction Plates together on one hub. Never attempt to re-use a previously installed Correction Plate. Following the Brake Align(R) procedures and diagram, install the Correction Plate onto the vehicle between the hub and the rotor. The V-notch in the Correction Plate is to be installed and aligned with the noted location of the "high spot" on the vehicle hub and marked wheel stud. Install the rotor onto the vehicle with the Correction Plate placed between the hub and the rotor. Be sure to install the rotor onto the hub in the same location as identified in Step 7. The rotor should then be secured onto the hub and tightened to the proper specification. The rotor should be dial indicated once more to assure that the rotor is now within specification. The brake system is now ready for the remaining service and assembly. Once the caliper has been installed, check to ensure that the rotor rotates freely. Parts Information Brake Align(R) Runout Correction Plates are available through the suppliers shown. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5345 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5346 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5347 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5348 Brake Align Order Form Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Brakes- Disc Brake Warranty Service And Procedures > Page 5349 Brake Rotor/Disc: Technical Service Bulletins Brakes - Minimum Allowable Rotor Thickness Bulletin No.: 04-05-23-002A Date: August 04, 2005 INFORMATION Subject: Brake Rotor Minimum Allowable Thickness After Refinish Specification Correction Models: 2001-2004 Buick Century, Regal 2002-2004 Buick Rendezvous 1997-2004 Chevrolet Venture 2001-2004 Chevrolet Impala, Monte Carlo 1997-2004 Oldsmobile Silhouette 2001-2002 Oldsmobile Intrigue 1997-1998 Pontiac Trans Sport 1999-2004 Pontiac Montana 2001-2004 Pontiac Aztek, Grand Prix Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 04-05-23-002 (Section 05 - Brakes). The current "Rotor Minimum Allowable Thickness After Refinish Specification" found in past Service Manual information is incorrect. The correct Minimum Allowable Thickness After Refinish specification shown in the table should be used to determine the service life of the rotor. This information has been updated within SI. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Page 5350 Brake Rotor/Disc: Specifications Front Brakes Rotor Discard Thickness* .............................................................................................. .............................................................................. 30.7 mm 1.21 in Rotor Maximum Allowable Assembled Lateral Runout ............................................................................................................................ 0.06 mm 0.002 in Rotor Maximum Allowable Scoring .......................................................................................................................................................... 1.50 mm 0.059 in Rotor Maximum Allowable Thickness Variation ..................................................................................................................................... 0.025 mm 0.001 in Rotor Minimum Allowable Thickness After Refinish ................................................................................................................................ 31.08 mm 1.22 in Rotor Thickness - New ........................................................................................................................ ......................................................... 32.2 mm 1.27 in Rear Brakes Rotor Discard Thickness* .......... .............................................................................................................................................................. ...... 9.0 mm 0.35 in Rotor Maximum Allowable Assembled Lateral Runout ............................................................................................................................ 0.06 mm 0.002 in Rotor Maximum Allowable Scoring .......................................................................................................................................................... 1.50 mm 0.059 in Rotor Maximum Allowable Thickness Variation ..................................................................................................................................... 0.025 mm 0.001 in Rotor Minimum Allowable Thickness After Refinish .................................................................................................................................. 10.0 mm 0.39 in Rotor Thickness - New ........................................................................................................................ ......................................................... 11.0 mm 0.43 in * All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet this specification. After refinishing the rotor, replace any rotor that does not meet the minimum thickness specification.t does not meet the minimum thickness specification. The content of this article has been updated by manual update # 04-05-23-002A dated August 4, 2005 for Rotor Minimum Allowable Thickness After Refinish. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement Brake Rotor/Disc: Service and Repair Brake Rotor Replacement Front BRAKE ROTOR REPLACEMENT - FRONT Tools Required ^ J41013 Rotor Resurfacing Kit ^ J 42450-A Wheel Hub Resurfacing Kit Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the tire and wheel assembly. 3. Install a C-clamp (2) over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 4. Using the C-clamp (2), compress the piston into the caliper bore lust enough to allow the caliper (1) to slide away from the rotor. 5. Remove the C-clamp (2). Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 6. Remove the caliper bracket bolts. Do not disconnect the brake flexible hose bolt. Remove the brake caliper and the caliper mounting bracket as an assembly (1) from the suspension knuckle and support the assembly with heavy mechanic's wire (2), or equivalent. Ensure that there is no tension on the hydraulic brake flexible hose. Refer to Brake Caliper Bracket Replacement Front on page 5-83. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 5353 7. Matchmark the position of the brake rotor (1) to the wheel studs. 8. Remove the brake rotor (1). Installation Procedure Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 1. Using the J 42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange (2). 2. Using the J41013, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor (1). 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange. 5. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 6. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 5354 7. Install the brake caliper and the brake caliper bracket as an assembly to the suspension knuckle. Refer to Brake Caliper Bracket Replacement Front. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. If the brake rotor was refinished or replaced, or if new brake pads were installed, burnish the pads and rotors. Refer to Burnishing Pads and Rotors. See: Brake Pad/Service and Repair/Burnishing Pads and Rotors Rear BRAKE ROTOR REPLACEMENT - REAR Tools Required ^ J41013 Rotor Resurfacing Kit ^ J42450-A Wheel Hub Resurfacing Kit Removal Procedure 1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle. 2. Remove the tire and wheel assembly. 3. Install a C-clamp over the body of the brake caliper, with the C-clamp ends against the rear of the caliper body and the outboard disc brake pad. 4. Using the C-clamp, compress the piston into the caliper bore just enough to allow the caliper to slide away from the rotor. 5. Remove the C-clamp. Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 6. Remove the caliper bracket bolts. Do not disconnect the brake flexible hose bolt. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 5355 7. Remove the brake caliper and the caliper mounting bracket as an assembly from the suspension knuckle and support the assembly with heavy mechanic's wire, or equivalent. Ensure that there is no tension on the hydraulic brake flexible hose. Refer to Brake Caliper Bracket Replacement - Rear. 8. Matchmark the position of the brake rotor (1) to the wheel studs. 9. Remove the brake rotor (1). Installation Procedure Important: Whenever the brake rotor has been separated from the hub/axle flange, any rust or contaminants should be cleaned from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in excessive assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 1. Using the J 42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the J41013, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor (1). 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange. 5. If the brake rotor was removed and installed as part of a brake system repair, measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. 6. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. 7. Install the brake caliper and the brake caliper bracket as an assembly to the suspension knuckle. 8. Install the tire and wheel assembly. 9. Lower the vehicle. 10. If the brake rotor was refinished or replaced, or if new brake pads were Installed, burnish the pads and rotors. Refer to Burnishing Pads and Rotors. See: Brake Pad/Service and Repair/Burnishing Pads and Rotors Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 5356 Brake Rotor/Disc: Service and Repair Disc Brake Backing Plate Replacement Disc Brake Backing Plate Replacement - Rear Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the rear wheels and tires. 3. Relieve the park brake system tension at the equalizer assembly. 4. Remove the rear caliper bracket. 5. Remove the rear rotor. 6. Disconnect and remove the rear park brake cable from the bracket at the rear wheel. 7. Disconnect the park brake cable return spring from the park brake actuator and bracket at the rear wheel. 8. Remove the rear hub. The rear hub, backing plate, park brake cable bracket, and park brake actuator will be removed as an assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 5357 9. Remove the 2 retainers (9) and the park brake cable bracket (8) from the park brake actuator (4). Position aside the rear hub. 10. Remove the park brake shoe and actuator (4) from the backing plate (7). Installation Procedure 1. Install the park brake shoe and actuator (4) onto the backing plate (7). 2. Position the park brake shoe, actuator (4), and backing plate (7) over the rear hub. 3. Install the park brake cable bracket (8) and the two retainers (9). 4. Install the rear hub. The rear hub, backing plate, park brake cable bracket, and park brake actuator will be installed as an assembly. 5. Install and connect the rear park brake cable to the bracket at the rear wheel. 6. Connect the park brake cable return spring to the park brake actuator and bracket at the rear wheel. 7. Install the rear rotor. 8. Install the rear caliper bracket. 9. Install the rear wheels and tires. 10. Adjust the park brake at the equalizer. 11. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 5358 Brake Rotor/Disc: Service and Repair Brake Rotor Assembled Lateral Runout (LRO) Correction BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION Important: Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. See: Testing and Inspection/Component Tests and General Diagnostics/Brake Rotor Thickness Variation Measurement Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. See: Testing and Inspection/Component Tests and General Diagnostics/Brake Rotor Assembled Lateral Runout (LRO) Measurement Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications Determine which method to use for the specific vehicle being repaired. Brake Rotor Assembled Lateral Runout (LRO) Correction - Indexing. The indexing method of correcting assembled LRO is most effective when the LRO specification is only exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used to achieve the best possible match of high spots to low spots between related components. Brake Rotor Assembled Lateral Runout (LRO) Correction - Correction Plates. The correction plate method of correcting assembled LRO involves the addition of a tapered plate between the brake rotor and the hub/axle flange. The correction plate method can be used to correct LRO that exceeds the specification by up to 0.23 mm (0.009 in). Brake Rotor Assembled Lateral Runout (LRO) Correction - On-Vehicle Lathe. The on-vehicle brake lathe method is used to bring the LRO to within specifications through compensating for LRO while refinishing the brake rotor. If the assembled LRO cannot be corrected using these methods, then other components must be suspected as causing and/or contributing to the LRO concern. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 5359 Brake Rotor/Disc: Service and Repair Brake Rotor Assembled Lateral Runout (LRO) Correction Methods Indexing BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION - INDEXING Tools Required: ^ J39544-KIT Torque-Limiting Socket Set, or equivalent ^ J 45101-100 Conical Brake Rotor Washers Important: ^ Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement. See: Testing and Inspection/Component Tests and General Diagnostics/Brake Rotor Thickness Variation Measurement ^ Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4,800-11,300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. See: Testing and Inspection/Component Tests and General Diagnostics/Brake Rotor Assembled Lateral Runout (LRO) Measurement 1. Remove the J45101-100 and the lug nuts that were installed during the assembled LRO measurement procedure. 2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 3. Index the brake rotor in a different orientation to the hub/axle flange. 4. Hold the rotor firmly in place against the hub/axle flange and install one of the J45101-100 (1) and one lug nut (2) onto the upper-most wheel stud. 5. Continue to hold the rotor secure and tighten the lug nut firmly by hand. 6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 7. Using the J 39544-KIT, or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 5360 8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. See: Testing and Inspection/Component Tests and General Diagnostics/Brake Rotor Assembled Lateral Runout (LRO) Measurement 9. Compare the amount of change between this measurement and the original measurement. 10. If this measurement is within specifications, proceed to step 14. 11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO measurement is obtained. 12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was originally. 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. See: Brake Rotor Assembled Lateral Runout (LRO) Correction 14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J45101-100 and the lug nuts. Correction Plates BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION - CORRECTION PLATES Tools Required ^ J 39544-KJT Torque-Limiting Socket Set, or equivalent ^ J 45101-100 Conical Brake Rotor Washers Important: ^ Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement on page 5-5& ^ Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. See: Testing and Inspection/Component Tests and General Diagnostics/Brake Rotor Assembled Lateral Runout (LRO) Measurement 1. Rotate the brake rotor to position the high spot, identified and marked during the brake rotor assembled LRO measurement procedure, to face upward. 2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 5361 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Select the correction plate, following the manufacturer's instructions, which has a specification closest to the assembled LRO measurement. For example: If the assembled LRO measurement was 0.076 mm (0.003 in), the 0.076 mm (0.003 in) correction plate would be used. If the measurement was 0.127 mm (0.005 in), the 0.152 mm (0.006 in) correction plate would be used. 5. Determine the positioning for the correction plate (1) using the high spot mark (3) made during the brake rotor assembled LRO measurement procedure. Important: ^ Do NOT install used correction plates in an attempt to correct brake rotor assembled lateral runout (LRO). ^ Do NOT stack up, or install more than one correction plate onto one hub/axle flange location, in an attempt to correct brake rotor assembled LRO. 6. Install the correction plate (1) onto the hub/axle flange, with the V-shaped notch (2) orientated to align with the high spot mark (3), that was positioned to face upward. 7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper orientation to the flange. 8. Hold the rotor firmly in place against the hub/axle flange and install one of the J 45101-100 (1) and one lug nut (2) onto the upper-most wheel stud. 9. Continue to hold the rotor secure and tighten the lug nut firmly by hand. 10. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly by hand in a star-pattern. 11. Using the J 39544-KIT or equivalent, tighten the lug nuts in a star-pattern to specification, in order to properly secure the rotor. 12. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout (LRQ) Measurement. See: Testing and Inspection/Component Tests and General Diagnostics/Brake Rotor Assembled Lateral Runout (LRO) Measurement 13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. See: Brake Rotor Assembled Lateral Runout (LRO) Correction Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 5362 14. If the brake rotor assembled LRO measurement is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J45101-100 and the lug nuts. On Vehicle Lathe BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION - ON-VEHICLE LATHE Tools Required: J 45101-100 Conical Brake Rotor Washers Important: ^ Brake rotor thickness variation MUST be checked BEFORE checking for assembled lateral runout (LRO). Thickness variation exceeding the maximum acceptable level can cause brake pulsation. Refer to Brake Rotor Thickness Variation Measurement on page 5-58. ^ Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable specification can cause thickness variation to develop in the brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi). Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. See: Testing and Inspection/Component Tests and General Diagnostics/Brake Rotor Assembled Lateral Runout (LRO) Measurement 1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any rotating components, such as the brake rotor. 2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO measurement procedure and/or the indexing correction procedure. 3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign particles or debris remaining. 4. Set up the lathe, following the manufacturer's instructions. 5. Refinish the brake rotor, following the brake lathe manufacturer's instructions. 6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement. See: Testing and Inspection/Component Tests and General Diagnostics/Brake Rotor Thickness Variation Measurement 7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. After replacing the rotor, proceed to Step 10. 8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 8.1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish 8.2. Using moderate pressure, apply the non-directional finish: ^ If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper ^ If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper 8.3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner 9. Remove the lathe from the vehicle. 10. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. See: Testing and Inspection/Component Tests and General Diagnostics/Brake Rotor Assembled Lateral Runout (LRO) Measurement 11. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer to Brake Rotor Assembled Lateral Runout (LRO) Correction See: Brake Rotor Assembled Lateral Runout (LRO) Correction. 12. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake pedal several times to secure the rotor in place before removing the J45101-100 and the lug nuts. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 5363 Brake Rotor/Disc: Service and Repair Brake Rotor Refinishing BRAKE ROTOR REFINISHING Tools Required ^ J 41013 Rotor Resurfacing Kit J 42450-A Wheel Hub Resurfacing Kit Important: ^ The disc brake rotors do not require refinishing as part of routine brake system service. New disc brake rotors do not require refinishing. Do not retinish disc brake rot6rs in an attempt to correct the following conditions: - Brake system noise - squeal, growl, groan - Uneven and/or premature disc brake pad wear - Superficial or cosmetic corrosion/rust of the disc brake rotor friction surface - Scoring of the disc brake rotor friction surface less than the maximum allowable specification ^ Before refinishing a brake rotor, the rotor MUST first be checked for adequate thickness to allow the rotor to be refinished and remain above the minimum allowable thickness after refinish specification. Refer to Brake Rotor Thickness Measurement. See: Testing and Inspection/Component Tests and General Diagnostics/Brake Rotor Thickness Variation Measurement Disc brake rotors should only be refinished if they have adequate thickness to be refinished and if one or more of the following conditions exist: - Thickness variation in excess of the maximum allowable specification - Excessive corrosion/rust and/or pitting - Cracks and/or heat spots - Excessive blueing discoloration - Scoring of the disc brake rotor surface in excess of the maximum allowable specification ^ Disc brake rotors may need to be refinished as part of the process for correcting brake rotor assembled lateral runout (LRO) that exceeds the maximum allowable specification. Important: Whenever the brake rotor has been separated from the hub/axle flange, clean any rust or contaminants from the hub/axle flange and the brake rotor mating surfaces. Failure to do this may result in increased assembled lateral runout (LRO) of the brake rotor, which could lead to brake pulsation. 1. Using the J 42450-A, thoroughly clean any rust or corrosion from the mating surface of the hub/axle flange. 2. Using the J 41013, thoroughly clean any rust or corrosion from the mating surface and mounting surface of the brake rotor. 3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign particles or debris remaining. 4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that all mounting attachments and adapters are clean and free of debris. 5. Ensure that any vibration dampening attachments are securely in place. 6. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor friction surfaces. 7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted to the lathe. 8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount the rotor to the lathe. 9. Following the brake lathe manufacturer's instructions, refinish the brake rotor. 10. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness Measurement. See: Testing and Inspection/Component Tests and General Diagnostics/Brake Rotor Thickness Variation Measurement 11. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the brake rotor must be replaced. 12. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-directional finish: 12.1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional finish 12.2. Using moderate pressure, apply the non-directional finish: - If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit aluminum oxide sandpaper - If the lathe is not equipped with a non-directional finishing tool, apply the finish with a sanding block and 150 grit aluminum oxide sandpaper 12.3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured alcohol, or an equivalent approved brake cleaner 13. Remove the brake rotor from the brake lathe. 14. Measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement. See: Testing and Inspection/Component Tests and General Diagnostics/Brake Rotor Assembled Lateral Runout (LRO) Measurement Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Service and Repair > Brake Rotor Replacement > Page 5364 15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction. See: Brake Rotor Assembled Lateral Runout (LRO) Correction Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Specifications Brake Bleeding: Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure Brake Bleeding: Service and Repair ABS Automated Bleed Procedure ABS Automated Bleed Procedure Bleeding the ABS System Perform a manual or pressure bleeding procedure. If the desired brake pedal height results are not achieved, perform the automated bleed procedure below. The procedure cycles the system valves and runs the pump in order to purge the air from the secondary circuits normally closed off during normal base brake operation and bleeding. The automated bleed procedure is recommended when air ingestion is suspected in the secondary circuits, or when the BPMV has been replaced. Automated Bleed Procedure Notice: The Auto Bleed Procedure may be terminated at any time during the process by pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto Bleed procedure will be given. After exiting the bleed procedure, relieve bleed pressure and disconnect bleed equipment per manufacturers instructions. Failure to properly relieve pressure may result in spilled brake fluid causing damage to components and painted surfaces. 1. Raise the vehicle on a suitable support. Refer to Vehicle Lifting. 2. Remove all four tire and wheel assemblies. 3. Inspect the brake system for leaks and visual damage. Refer to Brake Fluid Loss or Symptoms - Hydraulic Brakes. Repair or replace as needed. 4. Inspect the battery state of charge. 5. Install a scan tool. 6. Turn ON the ignition, with the engine OFF. 7. With the scan tool, establish communications with the EBCM. Select Special Functions. Select Automated Bleed from the Special Functions menu. 8. Bleed the base brake system. 9. Follow the scan tool directions until the desired brake pedal height is achieved. 10. If the bleed procedure is aborted, a malfunction exists. Perform the following steps before resuming the bleed procedure: ^ If a DTC is detected, refer to Diagnostic Trouble Code (DTC) List and diagnose the appropriate DTC. ^ If the brake pedal feels spongy, perform the conventional brake bleed procedure again. 11. When the desired pedal height is achieved, press the brake pedal in order to inspect for firmness. 12. Remove the scan tool. 13. Install the tire and wheel assemblies. 14. Inspect the brake fluid level. 15. Road test the vehicle while inspecting that the pedal remains high and firm. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 5376 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Manual) Hydraulic Brake System Bleeding (Manual) Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder - after all air has been purged from the front port of the master cylinder - loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve. 6. Install a transparent hose over the end of the bleeder valve. 7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. 10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal. 11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit. 12. With the right rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the right rear hydraulic circuitinstall a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve. 13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 14. With the left front wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left front hydraulic circuit install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve. 15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 16. With the left rear wheel hydraulic circuit bleeder valve tightened securely - after all air has been purged from the left rear hydraulic circuit - install a proper box-end wrench onto the RIGHT FRONT - wheel hydraulic circuit bleeder valve. 17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11. 18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps: 21.1. Inspect the brake system for external leaks. 21.2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system. 22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. Important: DO NOT allow the vehicle to be driven until it is diagnosed and repaired. 23. If the brake system warning lamp remains illuminated. Refer to Symptoms - Hydraulic Brakes. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 5377 Brake Bleeding: Service and Repair Hydraulic Brake System Bleeding (Pressure) Hydraulic Brake System Bleeding (Pressure) ^ Tools Required J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent - J 35589-A Brake Pressure Bleeder Adapter Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills. 2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes firm, in order to deplete the brake booster power reserve. 3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps: 3.1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add Delco Supreme II (R) (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm, if cap removal is necessary. 3.2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder. 3.3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder. 3.4. Reconnect the brake pipe to the master cylinder port and tighten securely. 3.5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal. 3.6. Loosen the same brake pipe to purge air from the open port of the master cylinder. 3.7. Tighten the brake pipe, then have the assistant slowly release the brake pedal. 3.8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master cylinder. 3.9. With the front brake pipe installed securely to the master cylinder, (after all air has been purged from the front port of the master cylinder), loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3-3.8. 3.10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened. 4. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II (R) (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 5. Install the J 35589-A to the brake master cylinder reservoir. 6. Check the brake fluid level in the J29532, or equivalent. Add Delco Supreme II (R) (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the half-full point. 7. Connect the J 29532, or equivalent, to the J 35589-A. 8. Charge the J 29532, or equivalent, air tank to 175 - 205 kPa (25 - 30 psi). 9. Open the J29532, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake system. 10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to completing this procedure. 11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve, then install a transparent hose over the end of the bleeder valve. 12. Submerge the open end of the transparent hose into a transparent container partially filled with Delco Supreme II (R) (GM P/N 12377967) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 13. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air bubbles stop flowing from the bleeder, then tighten the bleeder valve. 14. With the right rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the right rear hydraulic circuit), install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 12-13. 15. With the left front wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the left front hydraulic circuit), install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 12-13. 16. With the left rear wheel hydraulic circuit bleeder valve tightened securely, (after all air has been purged from the left rear hydraulic circuit), install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, install a transparent hose over the end of the bleeder valve, then repeat steps 12-13. 17. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened. 18. Close the J 29532, or equivalent, fluid tank valve, then disconnect the J 29532, or equivalent, from the J 35589-A. 19. Remove the J 35589-A from the brake master cylinder reservoir. 20. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme II (R) (GM P/N 12377967) or equivalent DOT-3 brake fluid Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 5378 from a clean, sealed brake fluid container. 21. Slowly depress and release the brake pedal. Observe the feel of the brake pedal. 22. If the brake pedal feels spongy perform the following steps: 22.1. Inspect the brake system for external leaks. 22.2. If equipped with Antilock Brakes, using a scan tool, perform the antilock brake system automated bleeding procedure to remove any air that may have been trapped in the BPMV. 23. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated. 24. If the brake system warning lamp remains illuminated, DO NOT allow the vehicle to be driven until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > ABS Automated Bleed Procedure > Page 5379 Brake Bleeding: Service and Repair Master Cylinder Bench Bleeding Master Cylinder Bench Bleeding Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. 1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 2. Remove the master cylinder reservoir cap and diaphragm. 3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment. 4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir. 5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid. 7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 inch), several times. Observe the flow of fluid coming from the ports. As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease. 8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles. 9. Remove the transparent hoses from the master cylinder reservoir. 10. Install the master cylinder reservoir cap and diaphragm. 11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills. 12. Remove the master cylinder from the vise. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Recalls for Brake Caliper: > 04049 > Jun > 04 > Recall - Front Brake Caliper Tightening Torque Technical Service Bulletin # 04049 Date: 040601 Recall - Front Brake Caliper Tightening Torque File In Section: Product Recalls Bulletin No.: 04049 Date: June, 2004 PRODUCT SAFETY RECALL SUBJECT: FRONT BRAKE CALIPER BOLT TORQUE MODELS: 2004 CHEVROLET IMPALA, MONTE CARLO 2004 PONTIAC GRAND PRIX CONDITION General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 model year Chevrolet Impala and Monte Carlo, and Pontiac Grand Prix vehicles. Some of these vehicles may have left and right front wheel assemblies in which the two bolts that attach the front brake caliper to the steering knuckle were not tightened adequately. If too much movement occurs between the caliper bracket and knuckle, the bolt(s) may back out or fracture. Depending on whether one or both bolts back out or fracture, the result can be 1) locking of the affected wheel during braking and an abrupt steering input in the direction of the locked wheel, 2) reduced braking and noise from the affected wheel, or 3) severing of a brake hose, increased brake pedal travel, and reduced steering control. If this were to occur, it could result in a vehicle crash without prior warning. CORRECTION Dealers are to tighten both bolts to the specified torque. VEHICLES INVOLVED Involved are certain 2004 model year Chevrolet Impala and Monte Carlo, and Pontiac Grand Prix vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned, will not have a report available in GM DealerWorld. For Canada & IPC: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. PARTS INFORMATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Recalls for Brake Caliper: > 04049 > Jun > 04 > Recall - Front Brake Caliper Tightening Torque > Page 5388 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO Customer Special Order. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. CUSTOMER NOTIFICATION - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Recalls for Brake Caliper: > 04049 > Jun > 04 > Recall - Front Brake Caliper Tightening Torque > Page 5389 Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for removing, cleaning, and reinstalling the bolts that attach both front brake caliper mounting brackets to the knuckles. 1. Raise the vehicle on a suitable hoist and support as necessary. 2. Remove both front tire and wheel assemblies. Important Do not remove the brake caliper from the mounting bracket. 3. Remove the two bolts (2) attaching the left front caliper mounting bracket (1) to the knuckle. Do not remove the bracket and caliper from the knuckle. 4. Using a wire brush, clean any threadlocker from the threads on the two bolts. 5. Apply adhesive (threadlocker), GM P/N 89021297 (Canadian P/N 10953488) or equivalent, to the threads of both bolts. 6. Reinstall the two bolts into the bracket. Tighten Tighten the bolts to 170 N.m (125 ft lb). 7. Repeat the procedure on the right side front caliper mounting bracket bolts. 8. Install both front tire and wheel assemblies. Tighten Tighten the wheel nuts to 140 N.m (103 ft lb). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Recalls for Brake Caliper: > 04049 > Jun > 04 > Recall - Front Brake Caliper Tightening Torque > Page 5390 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Recalls for Brake Caliper: > 04049 > Jun > 04 > Recall - Front Brake Caliper Tightening Torque > Page 5391 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Recalls for Brake Caliper: > NHTSA04V287000 > Jun > 04 > Recall 04V287000: Caliper Mounting Bolt Torque Brake Caliper: Recalls Recall 04V287000: Caliper Mounting Bolt Torque DEFECT: Certain passenger vehicles were produced with lower than specified torque on both front brake calipers to steering knuckle attachment bolts. With improper torque, the clamp load at the joint may not be adequate to prevent movement between the caliper bracket and knuckle. Depending on whether one or both bolts backs out or fractures, the result can be locking of the affected wheel during braking and an abrupt steering input in the direction of the locked wheel, reduced braking and noise from the affected wheel, or severing of a brake hose, increased brake pedal travel, and reduced steering control. Reduced braking or steering control could cause a crash. REMEDY: Dealers are to tighten both bolts to the specified torque. The manufacturer has reported that owner notification began on July 6, 2004. Owners may contact Chevrolet at 1-800-630-2438 or Pontiac at 1-800-620-7668. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04049 > Jun > 04 > Recall Front Brake Caliper Tightening Torque Technical Service Bulletin # 04049 Date: 040601 Recall - Front Brake Caliper Tightening Torque File In Section: Product Recalls Bulletin No.: 04049 Date: June, 2004 PRODUCT SAFETY RECALL SUBJECT: FRONT BRAKE CALIPER BOLT TORQUE MODELS: 2004 CHEVROLET IMPALA, MONTE CARLO 2004 PONTIAC GRAND PRIX CONDITION General Motors has decided that a defect, which relates to motor vehicle safety, exists in certain 2004 model year Chevrolet Impala and Monte Carlo, and Pontiac Grand Prix vehicles. Some of these vehicles may have left and right front wheel assemblies in which the two bolts that attach the front brake caliper to the steering knuckle were not tightened adequately. If too much movement occurs between the caliper bracket and knuckle, the bolt(s) may back out or fracture. Depending on whether one or both bolts back out or fracture, the result can be 1) locking of the affected wheel during braking and an abrupt steering input in the direction of the locked wheel, 2) reduced braking and noise from the affected wheel, or 3) severing of a brake hose, increased brake pedal travel, and reduced steering control. If this were to occur, it could result in a vehicle crash without prior warning. CORRECTION Dealers are to tighten both bolts to the specified torque. VEHICLES INVOLVED Involved are certain 2004 model year Chevrolet Impala and Monte Carlo, and Pontiac Grand Prix vehicles built within the VIN breakpoints shown. IMPORTANT: Dealers should confirm vehicle eligibility through GMVIS (GM Vehicle Inquiry System) prior to beginning recall repairs. [Not all vehicles within the above breakpoints may be involved.] For US: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared and will be loaded to the GM DealerWorld, Recall Information website. Dealers that have no involved vehicles currently assigned, will not have a report available in GM DealerWorld. For Canada & IPC: For dealers with involved vehicles, a Campaign Initiation Detail Report containing the complete Vehicle Identification Number, customer name and address data has been prepared, and is being furnished to involved dealers. Dealers that have no involved vehicles currently assigned, will not receive a report with the recall bulletin. The Campaign Initiation Detail Report may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this recall is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this recall. PARTS INFORMATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04049 > Jun > 04 > Recall Front Brake Caliper Tightening Torque > Page 5401 Parts required to complete this recall are to be obtained from General Motors Service Parts Operations (GMSPO). Please refer to your "involved vehicles listing" before ordering parts. Normal orders should be placed on a DRO = Daily Replenishment Order. In an emergency situation, parts should be ordered on a CSO Customer Special Order. COURTESY TRANSPORTATION The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranty. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product recall is very important in maintaining customer satisfaction. Dealers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. CLAIM INFORMATION Submit a Product Recall Claim with the information shown. CUSTOMER NOTIFICATION - For US and CANADA General Motors will notify customers of this recall on their vehicle (see copy of customer letter shown in this bulletin). CUSTOMER NOTIFICATION - For IPC Letters will be sent to known owners of record located within areas covered by the US National Traffic and Motor Vehicle Safety Act. For owners outside these areas, dealers should notify customers using the sample letter. DEALER RECALL RESPONSIBILITY - For US and IPC (US States, Territories, and Possessions) The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject to a recall of this type must be adequately repaired within a reasonable time after the customer has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima facie evidence of failure to repair within a reasonable time. If the condition is not adequately repaired within a reasonable time, the customer may be entitled to an identical or reasonably equivalent vehicle at no charge or to a refund of the purchase price less a reasonable allowance for depreciation. To avoid having to provide these burdensome remedies, every effort must be made to promptly schedule an appointment with each customer and to repair their vehicle as soon as possible. In the recall notification letters, customers are told how to contact the US National Highway Traffic Safety Administration if the recall is not completed within a reasonable time. DEALER RECALL RESPONSIBILITY - ALL All unsold new vehicles in dealers' possession and subject to this recall must be held and inspected/repaired per the service procedure of this recall bulletin before customers take possession of these vehicles. Dealers are to service all vehicles subject to this recall at no charge to customers, regardless of mileage, age of vehicle, or ownership, from this time forward. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04049 > Jun > 04 > Recall Front Brake Caliper Tightening Torque > Page 5402 Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer listing, are to be contacted by the dealer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is shown in this bulletin for your use in contacting customers. Recall follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in your dealership for service in the future, you must take the steps necessary to be sure the recall correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure The following procedure provides instructions for removing, cleaning, and reinstalling the bolts that attach both front brake caliper mounting brackets to the knuckles. 1. Raise the vehicle on a suitable hoist and support as necessary. 2. Remove both front tire and wheel assemblies. Important Do not remove the brake caliper from the mounting bracket. 3. Remove the two bolts (2) attaching the left front caliper mounting bracket (1) to the knuckle. Do not remove the bracket and caliper from the knuckle. 4. Using a wire brush, clean any threadlocker from the threads on the two bolts. 5. Apply adhesive (threadlocker), GM P/N 89021297 (Canadian P/N 10953488) or equivalent, to the threads of both bolts. 6. Reinstall the two bolts into the bracket. Tighten Tighten the bolts to 170 N.m (125 ft lb). 7. Repeat the procedure on the right side front caliper mounting bracket bolts. 8. Install both front tire and wheel assemblies. Tighten Tighten the wheel nuts to 140 N.m (103 ft lb). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04049 > Jun > 04 > Recall Front Brake Caliper Tightening Torque > Page 5403 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 04049 > Jun > 04 > Recall Front Brake Caliper Tightening Torque > Page 5404 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > NHTSA04V287000 > Jun > 04 > Recall 04V287000: Caliper Mounting Bolt Torque Brake Caliper: All Technical Service Bulletins Recall 04V287000: Caliper Mounting Bolt Torque DEFECT: Certain passenger vehicles were produced with lower than specified torque on both front brake calipers to steering knuckle attachment bolts. With improper torque, the clamp load at the joint may not be adequate to prevent movement between the caliper bracket and knuckle. Depending on whether one or both bolts backs out or fractures, the result can be locking of the affected wheel during braking and an abrupt steering input in the direction of the locked wheel, reduced braking and noise from the affected wheel, or severing of a brake hose, increased brake pedal travel, and reduced steering control. Reduced braking or steering control could cause a crash. REMEDY: Dealers are to tighten both bolts to the specified torque. The manufacturer has reported that owner notification began on July 6, 2004. Owners may contact Chevrolet at 1-800-630-2438 or Pontiac at 1-800-620-7668. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement Brake Caliper: Service and Repair Brake Caliper Bracket Replacement Front Brake Caliper Bracket Replacement - Front Removal Procedure Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics wire or equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the front brake pads. 3. Remove the caliper bracket bolts (2). 4. Remove the caliper bracket (1). Installation Procedure Important: To ensure that the proper clamp load will be present when installed. It is imperative that the threads on the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of all debris and inspected before proceeding with installation. 1. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the knuckle. 2. Apply THREADLOCKER, GM P/N 12345493 (Canadian P/N 10953488) or equivalent, to the threads of the brake caliper bracket bolts (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the caliper bracket (1) with the bracket bolts (2). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5411 ^ Tighten the caliper bracket bolts to 180 Nm (133 ft. lbs.). 4. Install the front brake pads. 5. Install the caliper. Rear Brake Caliper Bracket Replacement - Rear Removal Procedure Notice: Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake hose and in turn may cause a brake fluid leak. 1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanics wire or equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. 2. Remove the rear brake pads. 3. Remove the caliper bracket bolts (2). 4. Remove the caliper bracket (1). Installation Procedure Important: To ensure that the proper clamp load will be present when installed. It is imperative that the threads on the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of all debris and inspected before proceeding with installation. 1. Clean and visually inspect threads of the caliper bracket bolts (2) and mounting holes in the knuckle. 2. Apply THREADLOCKER, GM P/N 12345493 (Canadian P/N 10953488), or equivalent to the threads of the brake caliper bracket bolts (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the caliper bracket (1) with the bracket bolts (2). ^ Tighten the caliper bracket bolts to 115 Nm (85 ft. lbs.). 4. Install the rear brake pads. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5412 5. Install the caliper. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5413 Brake Caliper: Service and Repair Brake Caliper Overhaul Front Brake Caliper Overhaul - Front ^ Tools Required J 35777 Caliper Piston Seal Installer Removal Procedure 1. Remove the front brake caliper from the vehicle. Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious bodily injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. 2. Remove the brake caliper piston from the caliper bore by, directing low pressure compressed air into the caliper bore through the fluid inlet hole. 3. Using a small wooden or plastic tool, remove the caliper dust boot seal (2) from the seal counterbore in the caliper (1) and discard the boot seal. 4. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore and discard the piston seal. 5. Remove the bleeder valve (5) and cap (6) from the caliper (1). Important: Do not use abrasives to clean the brake caliper piston. 6. Clean the brake caliper, piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 7. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered air. 8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion. 9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5414 10. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 11. Inspect the caliper piston for cracks, scoring, and/or damage to the finished surface area. Replace the caliper piston if any of these conditions exist. Installation Procedure 1. Lubricate the new piston seal with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667) or equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container. 2. Install the lubricated, new piston seal into the caliper bore. 3. Install the caliper piston into the caliper bore. Press the piston to the bottom of the bore. 4. Install the new piston dust boot seal over the piston. 5. Use J 35777 to fully seat the caliper piston seal into the counterbore. 6. Install the bleeder valve and cap to the caliper and tighten the valve securely. 7. Install the front brake caliper to the vehicle. Rear Brake Caliper Overhaul - Rear Removal Procedure 1. Remove the rear brake caliper from the vehicle. Caution: Do not place fingers in front of the caliper piston(s) in an attempt to catch or protect it when applying compressed air. The piston(s) can fly out with force and could result in serious: bodily injury. Notice: Use clean cloths to pad interior of caliper housing during piston removal. Use just enough air to ease the pistons out of the bores. If the pistons are blown out, even with the padding provided, it may be damaged. 2. Remove the brake caliper, piston from the caliper bore by directing low pressure compressed air into the caliper bore through the fluid inlet hole. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5415 3. Remove the retaining ring that secures the dust boot to the caliper housing. 4. Remove the piston dust boot seal (2) from the seal counterbore in the caliper. Discard the boot seal. 5. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston seal. Important: Do not use abrasives to clean the brake caliper piston. 6. Clean the brake caliper, piston bore and seal counterbore, and the caliper piston with denatured alcohol, or equivalent. 7. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered air. 8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion. 9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a fine emery paper. If the imperfection cannot be removed, replace the caliper assembly. 10. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore, replace the caliper assembly. 11. Inspect the caliper piston for cracks, scoring, and/or damage to the chrome plating. Replace the caliper piston if any of these conditions exist. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5416 1. Lubricate the new piston seal (4) with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 2. Install the lubricated, new piston seal (4) into the caliper bore. 3. Apply a thin coat of Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667) or equivalent, DOT-3 brake fluid from a clean, sealed brake fluid container onto the outer surface area of the caliper piston (3). 4. Install the bottom half of the caliper piston (2) into the caliper bore. 5. Install the new piston dust boot seal (1) over the caliper piston (2). 6. Compress the caliper piston (2) to the bottom of the caliper bore. 7. Fully seat the piston dust boot seal (1) into caliper counterbore. 8. Install the retaining ring that secures the dust boot to the caliper housing. 9. Install the bleeder valve and cap to the caliper and tighten the valve securely. 10. Install the rear brake caliper to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5417 Brake Caliper: Service and Repair Brake Caliper Replacement Front Brake Caliper Replacement - Front Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Remove the front tire and the wheel assembly. 5. Hand tighten 2 wheel lug nuts to retain the rotor to the hub. 6. Install a large C-clamp (2) over the top of the brake caliper and against the back of the outboard brake pad. 7. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor. 8. Remove the C-clamp from the caliper. 9. Remove the brake hose-to-caliper bolt (1) from the caliper. Discard the 2 copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end. 10. Plug the opening in the front brake hose (2) to prevent excessive brake fluid loss and contamination. Important: Note the location of the caliper pin bolts. The leading caliper pin bolt, or top bolt, has a bushing as part of the assembly. The trailing caliper pin bolt, or bottom bolt, is a solid design. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5418 11. Remove the caliper pin bolts (1). Note the location of the caliper pin bolts. The leading caliper pin, or top bolt, has a bushing as part of the assembly. The trailing caliper pin, or bottom bolt, is a solid design. 12. Remove the caliper (2) from the rotor and the caliper bracket (3). 13. Inspect the caliper bolt boots in the caliper bracket for damage. Replace any damaged caliper bolt boots. 14. Inspect the caliper bolts (1) for corrosion or damage. If corrosion or damage is found, use new caliper pin bolts (1) when installing the caliper. Installation Procedure 1. If reusing the brake caliper pin bolts, wipe away any debris and old lubricant with a with a clean shop cloth. 2. Apply lubricant, GM P/N 18047666, or equivalent, to the brake caliper pin bolts. Apply a thin layer to the pin bushing (2) and to the caliper pin bolt shank (3, 4). Ensure that there is not a buildup of excess lubricant at the end of the leading caliper pin (1), in front of the bushing. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5419 3. Install the caliper (2) over the rotor and onto the caliper bracket (3). Notice: Refer to Fastener Notice in Service Precautions. Important: The leading caliper pin, or top bolt, has a bushing as part of the assembly. The trailing caliper pin, or bottom bolt, is a solid design. 4. Install the caliper pin bolts (1). The leading caliper pin bolt, or top bolt, has a bushing as part of the assembly. The trailing caliper pin bolt, or bottom bolt, is a solid design. Ensure that the bolt boots fit securely in the groove of the caliper pin bolts. If the boots are damaged, they must be replaced. ^ Tighten the bolts to 95 Nm (70 ft. lbs.). Important: Install NEW copper brake hose gaskets. 5. Assemble the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose (2). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5420 6. Install the brake hose-to-caliper bolt to the brake caliper. ^ Tighten the bolt to 54 Nm (40 ft. lbs.). 7. Remove the 2 wheel lug nuts retaining the rotor to the hub. 8. Install the front tire and the wheel assembly. 9. Lower the vehicle. 10. Fill the master cylinder to the proper level with clean brake fluid. 11. Bleed the brake system. 12. Inspect the hydraulic brake system for brake fluid leaks. Rear Brake Caliper Replacement - Rear Removal Procedure 1. Inspect the fluid level in the brake master cylinder reservoir. 2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, then remove brake fluid to the midway point before proceeding. 3. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 4. Remove the rear tire and the wheel assembly. 5. Hand tighten 2 wheel lug nuts to retain the rotor to the hub. 6. Install a large C-clamp (3) over the top of the brake caliper (2) and against the back of the outboard brake pad. 7. Tighten the C-clamp (3) until the caliper piston is pushed into the caliper bore enough to slide the caliper off the rotor. 8. Remove the C-clamp (3) from the caliper. 9. Remove the brake hose-to-caliper bolt (1) from the caliper. Discard the 2 copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end. 10. Plug the opening in the rear brake hose (2) to prevent excessive brake fluid loss and contamination. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5421 11. Remove the caliper bolts (1 and 3). 12. Remove the caliper (3) from the rotor (4) and the caliper bracket (1). 13. Inspect the caliper bracket bolt boots on the caliper bracket for the following conditions: ^ Cuts ^ Tears ^ Deterioration Replace any damaged caliper bracket bolt boots. 14. Inspect the caliper bolts (2) for corrosion or damage. If corrosion is found, use new caliper bolts, including bushings, when installing caliper. Installation Procedure 1. Install the caliper (3) over the rotor (4) and the caliper bracket (1). Ensure that the bushings are in place. 2. Lubricate the caliper bolts (1 and 3). Use silicone grease. Do not lubricate the threads. 3. Lubricate the 2 bolt boots (13 and 4) in the caliper bracket (12). Use silicone grease. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Brake Caliper Bracket Replacement > Page 5422 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the caliper bolts (1 and 3). Ensure that the bolt boots fit securely in the groove of the caliper bolts. Be sure not to pinch or tear the boots. If the boots are damaged, they must be replaced. ^ Tighten the bolts to 44 Nm (32 ft. lbs.). Important: Install NEW copper gaskets. 5. Assemble the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose (2). 6. Install the brake hose-to-caliper bolt to the brake caliper. ^ Tighten the bolt to 54 Nm (40 ft. lbs.). 7. Remove the 2 wheel lug nuts retaining the rotor to the hub. 8. Install the rear tire and the wheel assembly. 9. Lower the vehicle. 10. Fill the master cylinder to the proper level with clean brake fluid. 11. Bleed the brake system. 12. Inspect the hydraulic brake system for brake fluid leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications Brake Fluid: Capacity Specifications Information not supplied by the manufacturer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component Information > Specifications > Capacity Specifications > Page 5427 Brake Fluid: Fluid Type Specifications HYDRAULIC BRAKE SYSTEM Delco Supreme II Brake Fluid or equivalent DOT-3 brake fluid. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 5431 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector from brake fluid level sensor. 2. Remove the brake fluid level sensor. Using needle nose pliers, carefully depress the retaining tabs on the end of the brake fluid level sensor (1) and press the sensor through the reservoir to remove. Installation Procedure 1. Place the brake fluid level sensor (1) into the reservoir, press into place to secure the sensor retaining tabs. 2. Connect the electrical connector to the brake fluid level sensor (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement Brake Hose/Line: Service and Repair Brake Pipe Replacement Brake Pipe Replacement ^ Tools Required J 29803-A ISO Flaring Kit Caution: Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure. Notice: Do not use single lap flaring tools. Double lap flaring tools must be used to produce a flare strong enough to hold the system pressure. Using single lap flaring tools could cause system damage. 1. Obtain the recommended tubing and steel fitting nuts of the correct size. Outside diameter tubing is used in order to specify the size. 2. Cut the tubing to length. In order to determine the correct length, measure the old pipe using a string and adding 3 mm (1/8 inch) for each ISO flare. 3. Before starting the flare, install the fittings on the tubing. 4. Chamfer the inside and outside diameter of the pipe with the de-burring tool. 5. Remove all traces of lubricant from the brake pipe and the flaring tool. 6. Clamp the J29803-A ISO Flaring Kit. Tool body in a vise. 7. Select the correct size collet and forming mandrel (3) for the pipe size used. 8. Insert the proper forming mandrel into the tool body. 9. While holding the mandrel in place with a finger, thread the forcing screw until the screw makes contact with the forming mandrel and begins to move the forming mandrel. 10. When contact is made with the forming mandrel, turn the forcing screw back one complete turn. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 5436 11. Slide the clamping nut (1) over the brake pipe into the correct collet. Leave approximately 19 mm (3/4 inch) of tubing extending out the collet. 12. Insert the collet into the tool body. The brake pipe end must contact the face of the forming mandrel. 13. Tighten the clamping nut into the tool body very tight or the pipe may push out. 14. Wrench tighten the forcing screw until the screw bottoms. Do not over tighten the forcing screw or the flare may become over-sized. 15. Back the clamping nut out of the tool body. 16. Disassemble the clamping nut and collet. The flare is now ready for use. 17. Bend the pipe to match the old pipe. Maintain a clearance of 19 mm (3/4 inch) for all moving or vibrating components. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 5437 Brake Hose/Line: Service and Repair Brake Hose Replacement - Front Brake Hose Replacement - Front Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the front tire and wheel assembly. 3. Clean all dirt and foreign material from the brake hoses and brake pipe fitting. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. 4. Use a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose, then cap or plug the brake pipe fitting end. Do not bend the brake pipe or the bracket. 5. Remove the brake hose retaining clip from the hose mounting bracket. 6. Remove the hose from the bracket. 7. Remove the brake hose to caliper bolt (4) from the brake caliper (2). 8. Remove the brake hose (5) from the brake caliper (2). 9. Remove and discard the two copper brake hose gaskets (3). These gaskets may be stuck to the brake caliper and/or the brake hose end. Installation Procedure Important: Install NEW copper brake hose gaskets (3). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 5438 1. Assemble the NEW copper brake hose gaskets (3), and the brake hose bolt (4) to the brake hose. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the brake hose to caliper bolt to the brake caliper. ^ Tighten the brake hose to brake caliper bolt to 54 Nm (40 ft. lbs.). 3. With the weight of the vehicle on the suspension, install the brake hose into the bracket. There should not be any kinks in the hose. Align the hose fitting with the notch in the bracket. Use the hose paint stripe as a visual aid. 4. Install the retainer onto the hose fitting at the bracket. 5. Remove the rubber cap or plug from the exposed brake pipe fitting end. 6. Connect the brake pipe fitting to the brake hose: ^ Use a backup wrench on the hose fitting. ^ Do not bend the bracket or pipe. ^ Tighten the brake pipe fitting to 15 Nm (11 ft. lbs.). 7. Install the front tire and wheel assembly. 8. Ensure that the hose does not make contact with any part of the suspension. Check the hose in extreme right and extreme left turn conditions. If the hose makes contact, remove the hose and correct the condition. 9. Bleed the hydraulic brake system. 10. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 5439 Brake Hose/Line: Service and Repair Brake Hose Replacement - Rear Brake Hose Replacement - Rear Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the rear tire and wheel assembly. 3. Clean all dirt and foreign material from the brake hoses and brake pipe fitting. Important: Install a rubber cap or plug to the exposed brake pipe fitting end to prevent brake fluid loss and contamination. 4. Use a backup wrench on the hose fitting, disconnect the brake pipe fitting from the brake hose, then cap or plug the brake pipe fitting end. Do not bend the brake pipe or the bracket. 5. Remove the brake hose retaining clip from the hose mounting bracket. 6. Remove the hose from the bracket. 7. Remove the brake hose to caliper bolt (1) from the brake caliper. 3. Remove the brake hose (2) from the brake caliper. 9. Remove and discard the two copper brake hose gaskets (4). These gaskets may be stuck to the brake caliper and/or the brake hose end. Installation Procedure Important: Install NEW copper brake hose gaskets (4). 1. Assemble the NEW copper brake hose gaskets (4), and the brake hose bolt (1) to the brake hose (2). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the brake hose to caliper bolt (1) to the brake caliper. ^ Tighten the brake hose to brake caliper bolt to 54 Nm (40 ft. lbs.). 3. With the weight of the vehicle on the suspension, install the brake hose into the bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Pipe Replacement > Page 5440 There should not be any kinks in the hose. Align the hose fitting with the notch in the bracket. Use the hose paint stripe as a visual aid. 4. Install the retainer onto the hose fitting at the bracket. 5. Remove the rubber cap or plug from the exposed brake pipe fitting end. 6. Connect the brake pipe fitting to the brake hose: ^ Use a backup wrench on the hose fitting. ^ Do not bend the bracket or pipe. ^ Tighten the brake pipe fitting to 15 Nm (11 ft. lbs.). 7. Install the rear tire and wheel assembly. 8. Ensure that the hose does not make contact with any part of the suspension. If the hose makes contact, remove the hose and correct the condition. 9. Bleed the hydraulic brake system. 10. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair Brake Proportioning/Combination Valve: Service and Repair Proportioning Valve Replacement Removal Procedure Important: Do not wash the proportioning valve in any cleaning solution. The internal components are pre-lubricated with a special grease. 1. Remove the bracket (1) from the master cylinder. 2. Remove the master cylinder reservoir. 3. Remove the proportioning valve caps (1). 4. Remove the O-rings (5). 5. Remove the springs (2). 6. Remove the proportioning valve pistons (3). Carefully use needle nose pliers so that you do not damage the piston stems. 7. Remove the proportioning valve seals (4) from the pistons. 8. Inspect the proportioning valve pistons for corrosion and deformation. Replace the valve pistons if necessary. 9. Clean all of the parts in clean, denatured alcohol. 10. Dry the parts with non-lubricated compressed air. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Service and Repair > Page 5444 1. Lubricate the following parts with the silicone grease that is supplied in the repair kit: ^ O-rings (5) ^ Proportioning valve seals (4) ^ Proportioning valve piston stems (3) 2. Install new seals on the proportioning valve pistons. Ensure that the lip seals face up toward the cap. 3. Install the proportioning valve pistons and the seals in the master cylinder body. 4. Install the springs (2) in the master cylinder body. 5. Install new O-rings (5) in the grooves in the proportioning valve caps. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the proportioning valve caps (1) in the master cylinder body. ^ Tighten the proportioning valve caps to 27 Nm (20 ft. lbs.). 7. Install the bracket (1) to the master cylinder. 8. Install the master cylinder reservoir. 9. Bleed the brakes. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Bracket Replacement Brake Pressure Modulator Valve (BPMV) Bracket Replacement Removal Procedure 1. Turn the Ignition switch to the OFF position. 2. Remove the 2 BPMV mounting bracket nuts (3) and one bolt located near the bottom and one nut (1) located at the top of the BPMV mounting bracket (4) to the strut tower. 3. Disconnect the ground strap between the EBCM assembly and the chassis. 4. Remove the BPMV mounting bracket (4) from the vehicle. 5. Remove BPMV and EBCM assembly (2) from the BPMV mounting bracket (4). Installation Procedure 1. Install the BPMV and EBCM assembly (2) to the BPMV mounting bracket (4). 2. Install the BPMV bracket (4) to the strut tower. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 1 bolt and 3 nuts that attach the BPMV mounting bracket (4) to the strut tower. ^ Tighten the lower 2 BPMV mounting bracket nuts (3) and bolt to 10 Nm (89 inch lbs.). ^ Tighten the top nut (1) for BPMV mounting bracket (4) to strut tower to 3 Nm (27 inch lbs.). 4. Reconnect the ground strap between the EBCM assembly and the chassis. 5. Turn the ignition switch to the RUN position, engine off. 6. Perform the Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 5449 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Brake Pressure Modulator Valve (BPMV) Replacement Brake Pressure Modulator Valve (BPMV) Replacement Removal Procedure Caution: For safety reasons, the Brake Pressure Modulator Valve (BPMV) must not be repaired, the complete unit must be replaced. With the exception of the EBCM/EBTCM, no screws may be loosened. If screws are loosened, it will not be possible to get the brake circuits leak-tight and personal injury may result. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Turn the ignition switch to the OFF position. 2. Remove the attaching bolts for the cruise control module. 3. Swing the cruise control module off to the side. 4. Disengage the red locking tab from the connector (1). 5. Push down lock tab (1) and then move sliding connector cover (2) to the open position. 6. Disconnect the EBCM harness connector. Important: Note the locations of the brake pipes in order to aid in installation. 7. Disconnect the brake pipes (1) from the BPMV (2). 8. Swing the 4 brakes pipes out of the way only after covering the open pipes to avoid dripping or being contaminated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 5450 9. Disconnect the master cylinder brake pipes (2) from the BPMV (4). 10. It is not necessary to remove the brake pipes (2) from the master cylinder (1). 11. Swing the 2 master cylinder brake pipes out of the way only after covering the open pipes to avoid dripping or being contaminated. 12. Remove the 2 BPMV mounting bracket nuts (3) and 1 bolt located near the bottom and one nut (1) located at the top of the BPMV mounting bracket (4) to the strut tower. 13. Disconnect the ground strap between the EBCM assembly and the chassis. 14. Remove the BPMV mounting bracket (4) and EBCM assembly (2) from the vehicle. 15. Remove the 4 bolts (3) that connect the BPMV (1) to the mounting bracket (2). 16. Remove EBCM if replacing the BPMV only. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 5451 1. Install EBCM onto the BPMV(1) if replacing the BPMV only. 2. Install BPMV and EBCM as an assembly (1) to the mounting bracket (2). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the 4 bolts (3) that connects the BPMV assembly (1) to the mounting bracket (2). ^ Tighten the 4 bolts (3) that connect the BPMV (1) to the mounting bracket (2) to 10 Nm (89 inch lbs.). 4. Install the BPMV bracket (4) to the strut tower. 5. Install the 1 bolt and 3 nuts that attach the BPMV, mounting bracket (4) to the strut tower. ^ Tighten the lower 2 BPMV mounting bracket nuts (3) and bolt to 10 Nm (84 inch lbs.). ^ Tighten the top nut (1) for BPMV mounting bracket (4) to strut tower to 3 Nm (27 inch lbs.). Caution: Make sure brake pipes are correctly connected to brake pressure modulator valve. If brake pipes are switched by mistake wheel lockup will occur and personal injury may result The only two ways this condition can be detected are by using a Scan Tool or by doing an Antilock stop. Important: If a new BPMV is being installed, remove the shipping plugs from the valve openings during the next few steps when ready. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Brake Pressure Modulator Valve (BPMV) Bracket Replacement > Page 5452 6. Install the master cylinder brake pipes (2) into the BPMV (4). ^ Tighten the master cylinder brake pipe fittings to 24 Nm (18 ft. lbs.). 7. Install the brake pipes (1) on the BPMV (2). ^ Tighten all 4 brake pipe fittings to 24 Nm (18 ft. lbs.). 8. Reconnect the ground strap between the EBCM assembly and the chassis. 9. Connect the EBCM harness connector. 10. Push down lock tab (1) and then move sliding connector cover (2) back in home position to lock. 11. Insert red locking tab back in place. 12. Reinstall the cruise control module. 13. When all procedures have been completed, the automated ABS bleed procedure is required. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications Brake Master Cylinder: Specifications Master Cylinder Mounting Nuts 18 ft. lbs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul Brake Master Cylinder: Service and Repair Master Cylinder Overhaul Master Cylinder Overhaul Disassembly Procedure 1. Remove the brake master cylinder from the vehicle. 2. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary piston is accessible. 3. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the cap and diaphragm. 4. Remove the reservoir cap and diaphragm from the reservoir. 5. Inspect the reservoir cap and diaphragm for the following conditions. If any of these conditions are present, replace the affected components. ^ Cuts or cracks ^ Nicks or deformation 6. Remove the master cylinder reservoir from the master cylinder. 7. Using a smooth, round-ended tool, depress the primary piston (2) and remove the piston retainer. 8. Remove the primary piston assembly from the cylinder bore. 9. Plug the cylinder inlet ports and the rear outlet port. Apply low pressure, non-lubricated, filtered air into the front outlet port, in order the remove the secondary piston (1) with the primary (6) and secondary (5) seals, and the return spring. 10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from the secondary piston. Assembly Procedure Important: Do not use abrasives to clean the brake master cylinder bore. 1. Clean the interior and exterior of the master cylinder, the secondary piston (1), and the return spring in denatured alcohol, or equivalent. 2. Inspect the master cylinder bore, inlet and outlet ports, the secondary piston (1), and the return spring for cracks, scoring, pitting, and/or corrosion. Replace the master cylinder if any of these conditions exist. 3. Dry the master cylinder and the individual components with non-lubricated, filtered air. 4. Lubricate the master cylinder bore, the secondary piston (1), the return spring, and all of the individual overhaul components with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Assemble the lubricated, new primary seal (6) and retainer, and new secondary seal (5) onto the secondary piston. 6. Install the lubricated return spring and secondary piston assembly (1) into the cylinder bore. 7. Install the lubricated, new primary piston assembly (2) into the cylinder bore. 8. Using a smooth, round-ended tool, depress the primary piston (2) and install the new piston retainer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 5458 9. Install the master cylinder reservoir to the master cylinder. 10. Install the reservoir cap and diaphragm to the reservoir. 11. Install the master cylinder to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 5459 Brake Master Cylinder: Service and Repair Master Cylinder Replacement Master Cylinder Replacement Removal Procedure 1. Disconnect the electrical connector from the brake fluid level sensor. 2. If you are performing repairs on a 3.4L, non ABS Impala, it is necessary to remove the bracket (1) from the master cylinder. 3. Disconnect the brake pipes from the master cylinder. Important: Install a rubber cap or plug to the exposed brake pipe fitting ends in order to prevent brake fluid loss and contamination. 4. Plug the open brake pipe ends. 5. Remove master cylinder mounting nuts. 6. Remove the master cylinder from the vehicle. 7. Drain the master cylinder reservoir of all brake fluid. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 5460 1. Bench bleed the master cylinder. 2. Install the master cylinder to the vacuum brake booster. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the master cylinder mounting nuts. ^ Tighten the master cylinder mounting nuts to 25 Nm (18 ft. lbs.). 4. Remove the plugs from the brake pipes 5. Connect the brake pipes to the master cylinder. ^ Tighten the brake pipe fittings at the master cylinder to 15 Nm (11 ft. lbs.). 6. If you are performing repairs on a 3.4L, non ABS Impala, it is necessary to install the bracket (1) to the master cylinder. 7. Connect the electrical connector to the brake fluid level sensor. 8. Bleed the brake system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 5461 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement Master Cylinder Reservoir Replacement Removal Procedure 1. Remove the master cylinder from the vehicle. 2. Secure the master cylinder in a vise. Do not clamp the master cylinder body, secure only at the flange. 3. Remove the brake fluid level sensor. Using needle nose pliers, carefully depress the retaining tabs on the end of the brake fluid level sensor (1) and press the sensor through the reservoir to remove. 4. Carefully tap out the reservoir retaining pins. 5. Remove the reservoir from the master cylinder by pulling the reservoir straight up and away from the cylinder. 6. Remove the seals from the master cylinder. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 5462 1. Inspect the reservoir (1) for cracks or deformation. If found, replace the reservoir. 2. Clean the reservoir with denatured alcohol, or equivalent. 3. Dry the reservoir with non-lubricated, filtered air. 4. Lubricate the new seals (2) and the outer surface area of the reservoir-to-housing barrels with Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667) or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. 5. Install the lubricated seals (2), make sure they are fully seated. 6. Install the reservoir (1) to the master cylinder, by pressing the reservoir straight down on the master cylinder until the pin holes are aligned. 7. Carefully tap the reservoir retaining pins into place to secure the reservoir. 8. Place the brake fluid level sensor into the reservoir, press into place to secure the sensor retaining tabs. 9. Remove the master cylinder from the vise. 10. Install master cylinder to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Master Cylinder Overhaul > Page 5463 Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Filling Master Cylinder Reservoir Filling Notice: When adding fluid to the brake master cylinder reservoir, use only Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components. Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Service Precautions. 1. Visually inspect the brake fluid level through the brake master cylinder reservoir. 2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks. 3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level. 4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level. 5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions. 6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme II (R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Technical Service Bulletins > Brakes - Wheel Cylinder Inspection Guidelines Wheel Cylinder: Technical Service Bulletins Brakes - Wheel Cylinder Inspection Guidelines Bulletin No.: 03-05-24-001A Date: March 21, 2005 INFORMATION Subject: Service Information Regarding Rear Brake Drum Wheel Cylinder Inspections Models: 2005 and Prior GM Passenger Cars and Trucks 2005 and Prior Saturn Vehicles with Rear Drum Brakes Supercede: This bulletin is being revised add model years and include all GM vehicles. Please discard Corporate Bulletin Number 03-05-24-001 (Section 03 - Suspension). This bulletin provides information on proper inspection of rear drum brake wheel cylinders. Important: It is not recommended that dust boots be removed during inspection processes as dirt and debris could contaminate the wheel cylinder bore causing premature wear of the wheel cylinder. In addition, most bores should look damp and some lubricant may drip out from under the boot as a result of lubricant being present. All rear drum brake wheel cylinders are assembled with a lubricant to aid in assembly, provide an anti-corrosion coating to the cylinder bore, and lubricate internal rubber components. As a result of this lubrication process, it is not uncommon for some amount of lubricant to accumulate at the ends of the cylinder under the dust boot. Over time, the lubricant may work its way to the outside of the boot and cause an area of the boot to look damp. Evidence of a damp area on the boot does not indicate a leak in the cylinder. However, if there is excessive wetness (i.e. drips) coming from the boot area of the wheel cylinder, it could indicate a brake hydraulic fluid leak requiring wheel cylinder replacement. (Refer to the Wheel Cylinder Replacement procedures in the appropriate Service Manual.) Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Service and Repair Parking Brake Actuator: Service and Repair Park Brake Actuator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the rear tire and wheel assemblies. 3. Relieve the park brake system tension at the equalizer assembly. 4. Remove the rear caliper bracket. 5. Remove the rear rotor. 6. Disconnect and remove the rear park brake cable from the bracket at the rear wheel. 7. Disconnect the park brake cable return spring from the park brake actuator and bracket at the rear wheel. 8. Remove the rear hub. The rear hub, backing plate, park brake cable bracket, and park brake actuator will be removed as an assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component Information > Service and Repair > Page 5472 9. Remove the 2 retainers (9) and the park brake cable bracket (8) from the park brake actuator (4). Position the rear hub aside. 10. Remove the park brake shoe and actuator (4) from the backing plate (7). 11. Separate the actuator (4) from the park brake shoe. Installation Procedure 1. Assemble the actuator (4) to the park brake shoe. 2. Install the park brake shoe and actuator (4) onto the backing plate (7). 3. Position the park brake shoe, actuator (4), and backing plate (7) over the rear hub. 4. Install the park brake cable bracket (8) and the two retainers (9) ^ Tighten the bracket retainers to 10 Nm (89 inch lbs.). 5. Install the rear hub. The rear hub, backing plate, park brake cable bracket, and park brake actuator will be installed as an assembly. 6. Install and connect the rear park brake cable to the bracket at the rear wheel. 7. Connect the park brake cable return spring to the park brake actuator and bracket at the rear wheel. 8. Install the rear rotor. 9. Install the rear caliper bracket. 10. Install the rear tire and wheel assemblies. 11. Adjust the park brake system. 12. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Specifications Parking Brake Cable: Specifications Park Brake Cable Guide Mounting Bolt 18 ft. lbs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Front Park Brake Cable Replacement - Front Removal Procedure 1. Remove the left side instrument panel insulator. 2. Remove the left side carpet retainers. 3. Remove the lower center pillar trim panel on the left side. 4. Fold back the carpeting in order to gain access to the parking brake cable. 5. Remove the parking brake cable from the cable guides. 6. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 7. Remove the brake cable at the equalizer. 8. Lower the vehicle. 9. Remove the cable button end (1) from the parking brake lever clevis. 10. Remove the front cable (1) from the vehicle. Installation Procedure 1. Install the front cable (1) into the vehicle. 2. Connect the cable to the parking brake lever. 3. Install the cable button (1) in the lever clevis. 4. Install the cable button clip to the lever clevis. 5. Raise and suitably support the vehicle. Refer to Vehicle Lifting. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 5478 6. Tighten the nut on the equalizer in order to remove the slack in the cable. 7. Lower the vehicle. 8. Install the parking brake cable through the park brake cable guides. 9. Position the carpeting properly. 10. Install the lower center pillar trim panel on the left side. 11. Install the left side carpet retainers. 12. Install the left side instrument panel insulator. 13. Adjust the parking brake. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 5479 Parking Brake Cable: Service and Repair Park Brake Cable Replacement - Rear Park Brake Cable Replacement - Rear ^ Tools Required J 37043 Parking Brake Cable Release Tool Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Relieve the park brake cable tension at the equalizer. 3. Disconnect the front cable from the rear cable that is to be replaced. ^ For the right rear cable, disconnect the cable (3) from the clip (2). ^ For the left rear cable, fully remove the equalizer nut from the equalizer stud, which is part of the left rear cable. 4. Disconnect the retainer (1) that holds the cable to the support bracket. Use the J 37043 to release the retainer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 5480 5. Disconnect the park brake cable from the actuator lever. 6. Remove cable retaining pin from the support bracket and remove the park brake cable. Installation Procedure 1. Position the park brake cable into the support bracket and install the cable retaining pin. 2. Install the park brake cable to the actuator lever. 3. Connect the retainer (1) that holds the cable to the support bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 5481 4. Connect the rear cable to the front cable. ^ For the right rear cable, connect the cable (3) to the clip (2). ^ For the left rear cable, install the equalizer stud to the equalizer nut, which is part of the equalizer assembly. 5. Adjust the park brake. 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 5482 Parking Brake Cable: Service and Repair Park Brake Cable Equalizer Replacement Park Brake Cable Equalizer Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the left rear park brake cable and adjustment stud assembly from the equalizer assembly by removing the equalizer nut from the adjustment stud. 3. Disconnect the front park brake cable (1) from the right rear cable (3) at the connector clip (2). 4. Remove the equalizer assembly from the front park brake cable. Insert a flat bladed tool into the equalizer and lightly twist to reposition the equalizer retaining tab. This will release the assembly from the cable. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component Information > Service and Repair > Park Brake Cable Replacement - Front > Page 5483 1. Install the equalizer assembly to the front park brake cable. 2. Connect the front brake cable (1) to the right rear cable (3) at the connector clip (2). 3. Connect the left rear brake cable and adjustment stud assembly to the equalizer assembly by installing the adjustment stud to the equalizer nut. 4. Adjust the Park Brake System. 5. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair Parking Brake Shoe: Service and Repair Park Brake Shoe Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the rear tire and wheel assemblies. 3. Relieve the park brake system tension at the equalizer assembly. 4. Remove the rear caliper bracket. 5. Remove the rear rotor. 6. Disconnect and remove the rear park brake cable from the bracket at the rear wheel. 7. Disconnect the park brake cable return spring from the park brake actuator and bracket at the rear wheel. 8. Remove the rear hub. The rear hub, backing plate, park brake cable bracket, and park brake actuator will be removed as an assembly. 9. Remove the 2 retainers (9) and the park brake cable bracket (8) from the park brake actuator (4). Position the rear hub aside. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component Information > Service and Repair > Page 5487 10. Remove the park brake shoe and actuator (4) from the backing plate (7). 11. Separate the park brake shoe from the actuator. Installation Procedure 1. Assemble the park brake shoe to the actuator (4). 2. Install the park brake shoe and actuator (4) onto the backing plate (7). 3. Position the park brake shoe, actuator (4), and backing plate (7) over the rear hub. 4. Install the park brake cable bracket (8) and the two retainers (9). ^ Tighten the bracket retainers to 10 Nm (89 inch lbs.). 5. Install the rear hub. The rear hub, backing plate, park brake cable bracket, and park brake actuator will be installed as an assembly. 6. Install and connect the rear park brake cable to the bracket at the rear wheel. 7. Connect the park brake cable return spring to the park brake actuator and bracket at the rear wheel. 8. Install the rear rotor. 9. Install the rear caliper bracket. 10. Install the rear tire and wheel assemblies. 11. Adjust the park brake system. 12. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the left side instrument panel insulator. 2. Remove the left carpet retainers. 3. Disconnect the electrical connector from the switch. 4. Remove the mounting screw. 5. Remove the parking brake indicator switch (1). Installation Procedure 1. Install the parking brake indicator switch (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the mounting screw. ^ Tighten the mounting screw to 3 Nm (26 inch lbs.). 3. Connect the electrical connector to the switch. Check the operation of the switch. 4. Install the left carpet retainers. 5. Install the left side instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair Vacuum Brake Booster: Service and Repair Vacuum Brake Booster Replacement (3.8L) ^ Tools Required J 22805-B Power Brake Booster Holder Removal Procedure Caution: When replacing the power booster brake, make sure that the cruise control cable is not routed between the booster and the cowl. If the cable is damaged or pinched, it must be replaced. Failure to do this could result in personal injury. 1. Remove the left instrument panel insulator. 2. Disconnect the stop lamp switch electrical connector from the stop lamp switch. 3. Remove the retaining clip and disconnect the brake booster pushrod from the brake pedal. 4. Remove the cross vehicle brace. 5. Remove the fuel injector sight shield. 6. Disconnect the brake fluid level sensor electrical connector from the brake fluid level sensor. Important: It is not necessary to disconnect the brake pipes from the master cylinder to the Brake Pressure Modulator Valve. 7. Remove the two master cylinder retaining nuts and position the master cylinder aside. 8. Disconnect the vacuum brake booster, check valve from the brake booster. Position aside the vacuum hose and the check valve as an assembly. 9. Disconnect the throttle and cruise control cables from the throttle body. 10. Remove the throttle bracket, throttle cable, and the cruise control cable from the throttle body as an assembly. Position the throttle bracket and cables aside. 11. Rotate the engine forward for service access. 12. Remove the EGR valve wiring harness heat shield. 13. Remove the EGR valve. 14. Remove the transmission fluid filler tube bracket retainer and position the filler tube aside. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Page 5495 15. Attach the J 22805-B to the booster using the master cylinder retaining nuts. 16. Unlock the booster from the front of the cowl. Use a flat bladed tool to depress the brake booster locking tab (1) out of the cowl mounting flange, while turning the booster counterclockwise with a ratchet on the J 22805-B (2). 17. Remove the vacuum brake booster. Installation Procedure Notice: Internal components of this booster are not serviceable. The housing must not be unstaked and separated. Separating the housing will cause permanent deformation, preventing the booster from holding proper volume. Notice: Inspect the locking flanges on booster and mounting plate. Replace the booster and mounting plate if the locking flanges are bent or damaged. 1. Install the vacuum brake booster. Position the vacuum brake booster on the cowl counterclockwise from the final installation position so that the locking flanges on the vacuum brake booster and on the cowl mounting flange engage. Important: Ensure that the locking tab and the flanges are in the fully engaged position. 2. Turn the vacuum brake booster clockwise with a ratchet on the J 22805-B (2). DO NOT use a flat bladed tool in the locking tab to install the vacuum brake booster. When the vacuum brake booster is correctly installed, the locking tab (1) slides up the flange and engages the locking notch. 3. Remove the J 22805-B (2) from the installed vacuum brake booster. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Page 5496 4. Install the transmission fluid filler tube bracket retainer and reposition the filler tube. 5. Install the EGR valve. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the EGR valve wiring harness heat shield. ^ Tighten the EGR valve wiring harness heat shield nut and bolt to 10 Nm (89 inch lbs.). 7. Return the engine to the original rest position. Install the left and right engine mount struts. 8. Reposition the throttle bracket and cables to the throttle body. Install the throttle bracket, throttle cable, and the cruise control cable assembly to the throttle body. 9. Connect the throttle and cruise control cables to the throttle body. 10. Reposition and connect the vacuum hose and check valve assembly to the booster. 11. Reposition the master cylinder onto the booster and install the master cylinder retaining nuts. ^ Tighten the nuts to 25 Nm (18 ft. lbs.). 12. Connect the brake fluid level sensor electrical connector to the brake fluid level sensor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Page 5497 13. Install the fuel injector sight shield. 14. Install the cross vehicle brace. 15. Connect the brake booster pushrod to the brake pedal and install the retaining clip. 16. Connect the stop lamp switch electrical connector to the stop lamp switch. 17. Install the left instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster Check Valve > Component Information > Service and Repair Vacuum Brake Booster Check Valve: Service and Repair Vacuum Brake Booster Check Valve and/or Hose Replacement Removal Procedure 1. Remove the fuel injector sight shield, 3.8L engine only. 2. Disconnect the vacuum hose from the intake manifold. 3. Disconnect the vacuum hose (2) from the vacuum brake booster check valve (1). 4. Remove the vacuum brake booster check valve (1) from the vacuum brake booster. Installation Procedure 1. Install the vacuum brake booster check valve (1) onto the vacuum brake booster. 2. Connect the vacuum hose (2) to the vacuum brake booster (1). 3. Connect the vacuum hose to the intake manifold. 4. Install the fuel injector sight shield 3.8L engine only. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5505 Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5506 Electronic Brake Control Module: Service and Repair Electronic Brake Control Module (EBCM) Replacement Removal Procedure Notice: To prevent equipment damage, never connect or disconnect the wiring harness connection from the EBCM with the ignition switch in the ON position. 1. Turn the ignition switch to the OFF position. 2. Remove the fuel injector sight shield, 3.8 L engine only. 3. Remove the front fender upper diagonal brace. 4. Disconnect the accelerator and cruise control cable from the accelerator control cable bracket. 5. Disconnect the cruise control module from the left strut tower. It is not necessary to remove the cable from the module. Position the module and cables aside. 6. Remove the air cleaner intake duct. 7. Disengage the red locking tab (1) from connector lock tab. 8. Push down lock tab and then move sliding connector cover (2) to the open position. 9. Disconnect the EBCM harness connector. 10. Remove any dirt/debris from the assembly. 11. Remove the four EBCM to BPMV retainers. Important: Do not pry apart using a tool. Be careful not to damage BPMV surface. Important: Care must be taken not to damage the solenoid valves when the EBCM is removed from the BPMV. 12. Separate the EBCM from the BPMV by gently pulling apart until separated. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5507 1. Install the EBCM to the BPMV. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the four retainers that attach the EBCM to BPMV. ^ Tighten the retainers to 5 Nm (44 inch lbs.). 3. Connect the EBCM harness connector. 4. Push down lock tab (1) and then move sliding connector cover (2) back in the home position to lock. 5. Reengage the red locking tab (1) to the connected lock tab. 6. Install the air cleaner intake duct. 7. Reposition the module and cables. Connect the cruise control module to the left strut tower. 8. Connect the accelerator and cruise control cable to the accelerator control cable bracket. 9. Install the front fender upper diagonal brace. 10. Install the fuel injector sight shield, 3.8 L engine only. 11. Turn the ignition switch to the RUN position, do not start engine. 12. Perform the Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Diagrams > Page 5512 Brake Fluid Level Sensor/Switch: Service and Repair Master Cylinder Fluid Level Sensor Replacement Removal Procedure 1. Disconnect the electrical connector from brake fluid level sensor. 2. Remove the brake fluid level sensor. Using needle nose pliers, carefully depress the retaining tabs on the end of the brake fluid level sensor (1) and press the sensor through the reservoir to remove. Installation Procedure 1. Place the brake fluid level sensor (1) into the reservoir, press into place to secure the sensor retaining tabs. 2. Connect the electrical connector to the brake fluid level sensor (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the left side instrument panel insulator. 2. Remove the left carpet retainers. 3. Disconnect the electrical connector from the switch. 4. Remove the mounting screw. 5. Remove the parking brake indicator switch (1). Installation Procedure 1. Install the parking brake indicator switch (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the mounting screw. ^ Tighten the mounting screw to 3 Nm (26 inch lbs.). 3. Connect the electrical connector to the switch. Check the operation of the switch. 4. Install the left carpet retainers. 5. Install the left side instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair Traction Control Switch: Service and Repair Traction Control Switch Replacement (Impala) Removal Procedure 1. If equipped with column shift, apply the parking brake. 2. If equipped with column shift, position the transaxle shift control indicator to 1. 3. Adjust the steering wheel for access. 4. Remove the ignition switch cylinder bezel. 5. Remove the LH instrument panel (IP) fuse block access opening cover. 6. Remove the LH IP cluster trim plate screws. 7. Remove the IP cluster trim plate for access. Start at the left side of the IP cluster trim plate, grasp the trim plate and carefully pull rearward. Disengage enough IP cluster trim plate retainers in order to gain access the traction control switch. 8. Disconnect the electrical connector (1) from the traction control switch (2). 9. Remove the traction control switch (1) from the IF, cluster trim plate (2). Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction Control Switch > Component Information > Service and Repair > Page 5519 1. Install the traction control switch (1) to the IP cluster trim plate (2). 2. Connect the electrical connector (1) to the traction control switch (2). 3. Align and carefully press the IP cluster trim plate into the IP trim pad. Make sure all of the retainers are fully engaged. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the LH IP cluster trim plate screws. ^ Tighten the IP cluster trim plate screws to 2 Nm (18 inch lbs.). 5. Install the LH instrument panel (IP) fuse block access opening covers. 6. Install the ignition switch cylinder bezel. 7. Return the steering wheel to the original position. 8. If equipped with a column shift, position the transaxle shift control indicator to Park. 9. If equipped with column shift, release the parking brake. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement - Front Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement - Front Wheel Speed Sensor Replacement - Front Removal Procedure Important: The front wheel speed sensors and rings are integral with the hub and bearing assemblies. If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. Do not service the harness pigtail individually because the harness pigtail is part of the sensor. 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting. 2. Remove the front tire and wheel assembly. 3. Disconnect the front wheel speed sensor jumper harness electrical connector (1). 4. Remove the hub and bearing assembly (2). Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement - Front > Page 5524 1. Install the hub and bearing assembly (2) to the vehicle. 2. Install the front wheel speed sensor jumper harness electrical connector (1). 3. Install the wheel and tire assembly. 4. Lower the vehicle. 5. Turn the ignition switch to the ON position with the engine off. 6. Perform the Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement - Front > Page 5525 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement - Rear Wheel Speed Sensor Replacement - Rear Removal Procedure Important: The rear wheel speed sensors and rings are integral with the hub and bearing assemblies. If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. 1. Raise and support the vehicle on a suitable hoist. Refer to Vehicle Lifting. 2. Remove the rear tire and wheel assembly. 3. Disconnect the electrical connector from the rear wheel speed sensor. 4. Remove the hub and bearing assembly (1). Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement - Front > Page 5526 1. Install the hub and bearing assembly (1) to the vehicle. 2. Connect the electrical connector to the rear wheel speed sensor. 3. Install the wheel and tire assembly. 4. Lower the vehicle. 5. Turn the ignition switch to the ON position, with the engine off. 6. Perform the Diagnostic System Check - ABS. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder Replacement Removal Procedure Important: Perform the body control module (BCM) theft deterrent relearn procedure whenever you replace the ignition switch lock cylinder. 1. Disconnect the negative battery cable. 2. Remove the instrument panel (I/P) cluster trim plate. 3. Insert the key and turn the ignition lock cylinder to the ON/RUN position. 4. Using a small curved tool or an L-shaped hex wrench, depress and hold the detent on the ignition lock cylinder. Access the detent by placing the tool through the I/P opening to the right of the ignition switch. If you cannot locate the detent with the tool, lower the ignition switch away from the I/P. Refer to Ignition Switch Replacement. 5. Using the key as an aid, pull to remove the lock cylinder from the switch. 6. Remove the key from the lock cylinder. 7. If the cylinder does not rotate or is seized, follow the procedure in the ignition switch replacement. Refer to Ignition Switch Replacement. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 5533 1. Code the ignition lock cylinder, if necessary. Refer to Key and Lock Cylinder Coding in General Information. 2. Insert the key and turn the lock cylinder to the ON/RUN position. 3. Position the lock cylinder to the ignition switch. Press the cylinder into place. If you turned the key slightly while removing the lock cylinder, you may have to align the white colored ignition switch rotor (1) with the lock cylinder (2). You can rotate the ignition switch rotor (1) with your finger. 4. Turn the key to the OFF position and remove the key. 5. Install the I/P cluster trim plate. 6. Connect the negative battery cable. 7. If you installed a new lock cylinder, perform the BCM theft deterrent relearn procedure. Refer to Body Control Module (BCM) Programming/RPO Configuration in Body Control System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions Jump Starting: Service Precautions CAUTION: - Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. - Do not connect a jumper cable directly to the negative terminal of a discharged battery to prevent sparking and possible explosion of battery gases. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Jump Starting > System Information > Service Precautions > Page 5538 Jump Starting: Service and Repair JUMP STARTING IN CASE OF EMERGENCY CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid. Batteries supply levels of electrical current high enough to cause burns. Therefore, in order to reduce the risk of personal injury while working near a battery, observe the following guidelines: - Always shield your eyes. - Avoid leaning over the battery whenever possible. - Do not expose the battery to open flames or sparks. - Do not allow battery acid to contact the eyes or the skin. Flush any contacted areas with water immediately and thoroughly. - Get medical help. NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the vehicle or equipment being used to jump start the engine is also 12 volt, negative ground. Use of any other type of system will damage the vehicle's electrical components. 1. Position the vehicle with the booster battery so that the jumper cables will reach. - Do not let the 2 vehicles touch. - Make sure that the jumper cables do not have loose ends, or missing insulation. 2. Place an automatic transmission in PARK. If equipped with a manual transmission, place in NEUTRAL and block the wheels. 3. Turn OFF all electrical loads on both vehicles that are not needed. 4. Turn OFF the ignition on both vehicles. 5. Connect the red positive (+) cable to the battery positive (+) terminal (2) of the vehicle with the discharged battery. Use a remote positive (+) terminal if the vehicle has one. 6. Connect the red positive (+) cable to the positive (+) terminal (1) of the booster battery. Use a remote positive (+) terminal if the vehicle has one. 7. Connect the black negative (-) cable to the negative (-) terminal (3) of the booster battery. 8. The final connection is made to a heavy, unpainted metal engine part (4) of the vehicle with the discharged battery. This final attachment must be at least 46 cm (18 in) away from the dead battery. CAUTION: Do not connect a jumper cable directly to the negative terminal of a discharged battery to prevent sparking and possible explosion of battery gases. 9. Start the engine of the vehicle that is providing the boost. 10. Crank the engine of the vehicle with the discharged battery. NOTE: Never operate the starter motor more than 15 seconds at a time without pausing in order to allow it to cool for at least 2 minutes. Overheating will damage the starter motor. 11. The black negative (-) cable must be first disconnected from the vehicle that was boosted (4). 12. Disconnect the black negative (-) cable from the negative (-) terminal (3) of the booster battery. 13. Disconnect the red positive (+) cable from the positive (+) terminal (1) of the booster battery. NOTE: Do not let the cable end touch any metal. Damage to the battery and other components may result. 14. Disconnect the red positive (+) cable from the remote positive (+) terminal (2) of the vehicle with the discharged battery. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure Negative: Service and Repair Battery Negative Cable Disconnect/Connect Procedure REMOVAL PROCEDURE 1. Record all of the vehicle preset radio stations. CAUTION: Refer to SIR Caution in Service Precautions. - Refer to Battery Disconnect Caution in Service Precautions. 2. Turn OFF all the lamps and the accessories. 3. Ensure the ignition switch is in the OFF position. 4. Disconnect the negative battery cable from the battery. INSTALLATION PROCEDURE 1. Connect the negative battery cable to the battery. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Clean any existing oxidation from the contact face of the battery terminal and battery cable using a wire brush before installing the battery cable to the battery terminal. Tighten Tighten the terminal bolt to 15 N.m (11 lb ft). 2. Set the clock and program the radio stations back into the radio as recorded at the beginning of the procedure. Refer to Radio/Audio System Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure > Page 5544 Description and Operation in Radio, Stereo and Compact Disc. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure > Page 5545 Negative: Service and Repair Battery Negative Cable Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. IMPORTANT: When replacing battery cables be sure to use replacement cables that are the same type, gage and length. 2. Disconnect the positive battery cable. 3. Remove the ground wire bolt and the ground wire from the frame. 4. Remove the remote positive stud cover Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure > Page 5546 5. Remove the positive cable junction block lead nut (1). 6. Remove the positive battery cable (2) from the underhood accessory wiring junction block. 7. Raise and support the vehicle. Refer to vehicle lifting. 8. Remove the front lower air deflector. 9. Remove the transaxle stud nut and the ground wire from the transaxle stud. 10. Remove the positive battery cable nut (8) from the starter motor BAT terminal. 11. Remove the positive battery cable (9) from the starter motor BAT terminal. 12. Unclip and remove the battery cable harness from the retainers (2,3,4). 13. Remove the battery cable harness from the vehicle. 14. Remove the negative battery cable from the wiring harness conduit. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure > Page 5547 INSTALLATION PROCEDURE 1. Install the negative battery cable into the wiring harness conduit. 2. Install the battery cable harness to the retainers (2,3,4). 3. Install the positive battery cable (9) to the starter motor BAT terminal. 4. Install the positive battery cable nut (8) to the starter motor BAT terminal. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 10 N.m (89 lb in). 5. Install the ground wire and the transaxle stud nut. Tighten Tighten the nut to 25 N.m (18 lb ft). 6. Install the front lower air deflector. 7. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure > Page 5548 8. Install the positive battery cable (2) to the underhood accessory wiring junction block. 9. Install the positive cable junction block lead nut (1). Tighten Tighten the nut to 10 N.m (89 lb in). 10. Install the remote positive stud cover. 11. Install the ground wire and the bolt to the frame. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Negative, Battery Cable > System Information > Service and Repair > Battery Negative Cable Disconnect/Connect Procedure > Page 5549 Tighten Tighten the bolt to 10 N.m (89 lb in). 12. Connect the positive battery cable. Tighten Tighten the terminal bolt to 15 N.m (11 ft lb). 13. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair Positive: Service and Repair BATTERY POSITIVE CABLE REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. IMPORTANT: When replacing battery cables be sure to use replacement cables that are the same type, gage and length. 2. Disconnect the positive battery cable. 3. Remove the ground wire bolt and the ground wire from the frame. 4. Remove the remote positive stud cover Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Page 5553 5. Remove the positive cable junction block lead nut (1). 6. Remove the positive battery cable (2) from the underhood accessory wiring junction block. 7. Raise and support the vehicle. Refer to vehicle lifting. 8. Remove the front lower air deflector. 9. Remove the transaxle stud nut and the ground wire from the transaxle stud. 10. Remove the positive battery cable nut (8) from the starter motor BAT terminal. 11. Remove the positive battery cable (9) from the starter motor BAT terminal. 12. Unclip and remove the battery cable harness from the retainers (2,3,4). 13. Remove the battery cable harness from the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Page 5554 14. Remove the positive battery cable from the wiring harness conduit. INSTALLATION PROCEDURE 1. Install the positive battery cable into the wiring harness conduit. 2. Install the battery cable harness to the retainers (2,3,4). 3. Install the positive battery cable (9) to the starter motor BAT terminal. 4. Install the positive Notice in Service Precautions. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 10 N.m (89 lb in). 5. Install the ground wire and the transaxle stud nut. Tighten Tighten the nut to 25 N.m (18 lb ft). 6. Install the front lower air deflector. 7. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Page 5555 8. Install the positive battery cable (2) to the underhood accessory wiring junction block. 9. Install the positive cable junction block lead nut (1). Tighten Tighten the nut to 10 N.m (89 lb in). 10. Install the remote positive stud cover. 11. Install the ground wire and the bolt to the frame. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Battery > Battery Cable > Positive, Battery Cable > System Information > Service and Repair > Page 5556 Tighten Tighten the bolt to 10 N.m (89 lb in). 12. Connect the positive battery cable. Tighten Tighten the terminal bolt to 15 N.m (11 ft lb). 13. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Specifications Generator Usage Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions Alternator: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5563 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5564 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5565 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5566 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5567 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5568 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5569 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5570 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5571 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5572 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5573 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5574 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5575 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5576 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5577 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5578 Alternator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5579 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5580 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5581 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5582 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5583 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5584 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5585 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5586 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5587 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5588 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5589 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5590 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5591 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5592 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5593 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5594 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5595 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5596 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5597 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5598 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5599 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5600 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5601 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5602 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5603 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5604 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5605 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Diagram Information and Instructions > Page 5606 Generator Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Diagrams > Page 5607 Alternator: Description and Operation GENERATOR The generators feature the following major components: - The delta stator - The rectifier bridge - The rotor with slip rings and brushes - A conventional pulley - The regulator The pulley and the fan cool the slip ring and the frame. The generator features permanently lubricated bearings. Service should only include tightening of mount components. Otherwise, replace the generator as a complete unit. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement Alternator: Service and Repair Generator Bracket Replacement REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the generator. 3. Remove the generator bracket bolts. 4. Remove the generator bracket. 5. Remove the engine lift hook. INSTALLATION PROCEDURE 1. Install the engine lift hook. 2. Install the generator bracket to the engine. 3. Install the generator bracket bolts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 50 N.m (37 lb ft). 4. Install the generator. 5. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 5610 Alternator: Service and Repair Generator Brace Replacement REMOVAL PROCEDURE 1. Remove the generator rear brace nut (5). 2. Remove the generator rear brace bolt (3). 3. Remove the generator rear brace (4). INSTALLATION PROCEDURE 1. Install the generator rear brace (4). 2. Install the generator rear brace bolt (3). 3. Install the generator rear brace nut (5). 4. Tighten the generator bolt and nut in the following sequence: NOTE: Refer to Fastener Notice in Service Precautions. Tighten 1. Tighten the generator rear brace bolt (3) to 50 N.m (37 lb ft). 2. Tighten the generator rear brace nut (5) to 50 N.m (37 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 5611 Alternator: Service and Repair Generator Replacement REMOVAL PROCEDURE The Delphi CS130D (K43) 102 ampere generator is serviced as a complete unit only. The Bosch NCB1 (KG7) 125 ampere generator is serviced as a complete unit only. 1. Disconnect the negative battery cable 2. Remove the drive belt from the generator. 3. Position aside the protective boot from the generator output BAT terminal for access. 4. Remove the generator output BAT terminal nut and remove the positive battery lead from the generator. 5. Remove the generator rear brace nut (5). 6. Remove the generator rear brace bolt (3). 7. Remove the generator rear brace (4). 8. Remove the pivot bolt (1) from the generator. 9. Remove the stud (3) and bolt (2) from the generator. IMPORTANT: Spacer (4) is only present if equipped with the Bosch NCB1 (KG7) 125 ampere generator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 5612 10. Disconnect the electrical connector from the generator. 11. Remove the generator. INSTALLATION PROCEDURE 1. Position the generator to the engine. 2. Connect the electrical connector to the generator. 3. Install the generator stud (3) and spacer (4) through the hole in the generator, finger tight. IMPORTANT: Spacer (4) is only present if equipped with the Bosch NCB1 (KG7) 25 ampere generator. 4. Install the generator bolt (2) to the hole in generator, finger tight. 5. Install the pivot bolt (1) to the generator, finger tight. 6. Tighten the generator bolts in the following sequence: NOTE: Refer to Fastener Notice in Service Precautions. 6.1. Tighten Tighten the generator pivot bolt (1) to 50 N.m (37 lb ft). 6.2. Tighten Tighten the generator stud (3) to 50 N.m (37 lb ft). 6.3. Tighten Tighten the generator bolt (2) to 50 N.m (37 lb ft). 7. Install the positive battery lead and the generator output BAT terminal nut. Tighten Tighten the nut to 20 N.m (15 lb ft). 8. Install the protective boot on the generator output BAT terminal. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information > Service and Repair > Generator Bracket Replacement > Page 5613 9. Install the generator rear brace (4). 10. Install the generator rear brace bolt (3). 11. Install the generator rear brace nut (5). 12. Tighten the generator bolts in the following sequence: Tighten 1. Tighten the generator rear brace bolt (3) to 50 N.m (37 lb ft). 2. Tighten the generator rear brace nut (5) to 50 N.m (37 lb ft). 3. Install the drive belt. 4. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Description and Operation Voltage Regulator: Description and Operation The voltage regulator controls the rotor field current in order to limit the system voltage. When the field current is on, the regulator switches the current on and off at a rate of 400 cycles per second in order to perform the following functions: - Radio noise control - Obtain the correct average current needed for proper system voltage control At high speeds, the on-time may be 10 percent with the off-time at 90 percent. At low speeds, the on-time may be 90 percent and the off-time 10 percent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair Ignition Switch Lock Cylinder: Service and Repair Ignition Switch Lock Cylinder Replacement Removal Procedure Important: Perform the body control module (BCM) theft deterrent relearn procedure whenever you replace the ignition switch lock cylinder. 1. Disconnect the negative battery cable. 2. Remove the instrument panel (I/P) cluster trim plate. 3. Insert the key and turn the ignition lock cylinder to the ON/RUN position. 4. Using a small curved tool or an L-shaped hex wrench, depress and hold the detent on the ignition lock cylinder. Access the detent by placing the tool through the I/P opening to the right of the ignition switch. If you cannot locate the detent with the tool, lower the ignition switch away from the I/P. Refer to Ignition Switch Replacement. 5. Using the key as an aid, pull to remove the lock cylinder from the switch. 6. Remove the key from the lock cylinder. 7. If the cylinder does not rotate or is seized, follow the procedure in the ignition switch replacement. Refer to Ignition Switch Replacement. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Service and Repair > Page 5622 1. Code the ignition lock cylinder, if necessary. Refer to Key and Lock Cylinder Coding in General Information. 2. Insert the key and turn the lock cylinder to the ON/RUN position. 3. Position the lock cylinder to the ignition switch. Press the cylinder into place. If you turned the key slightly while removing the lock cylinder, you may have to align the white colored ignition switch rotor (1) with the lock cylinder (2). You can rotate the ignition switch rotor (1) with your finger. 4. Turn the key to the OFF position and remove the key. 5. Install the I/P cluster trim plate. 6. Connect the negative battery cable. 7. If you installed a new lock cylinder, perform the BCM theft deterrent relearn procedure. Refer to Body Control Module (BCM) Programming/RPO Configuration in Body Control System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 5627 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 5628 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 5629 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions Starter Motor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5634 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5635 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5636 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5637 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5638 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5639 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5640 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5641 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5642 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5643 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5644 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5645 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5646 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5647 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5648 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5649 Starter Motor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5650 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5651 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5652 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5653 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5654 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5655 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5656 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5657 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5658 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5659 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5660 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5661 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5662 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5663 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5664 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5665 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5666 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5667 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5668 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5669 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5670 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5671 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5672 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5673 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5674 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5675 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 5676 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 5677 Starter Motor Usage Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 5678 Starter Motor: Service and Repair REMOVAL PROCEDURE 1. Disconnect the negative battery negative cable. IMPORTANT: The starter motor on this vehicle is NOT serviceable and must be replaced as a complete unit. 2. Raise and support the vehicle. Refer to vehicle lifting. 3. Remove the lower air deflector. 4. Remove the torque converter covers. 5. Remove the starter solenoid BAT terminal nut (6) and the positive battery cable (7) from the starter motor. 6. Remove the starter solenoid S terminal nut (5) and the starter solenoid wire (4) from the starter motor. 7. Remove the starter bolts (1,2) and the starter motor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information > Diagrams > Page 5679 1. Align the starter motor to the engine. 2. Install the starter bolts (1,2) finger tight until seated. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolts to 43 N.m (32 lb ft). 3. Install the positive battery cable (7) and the solenoid BAT terminal nut (6) finger tight to the starter motor. Install the starter solenoid wire (4) and the starter solenoid S terminal nut (5) finger tight to the starter motor. Tighten Tighten the solenoid BAT terminal nut (6) to 10 N.m (89 lb in). - Tighten the starter solenoid S terminal nut (5) to 2.3 N.m (20.5 lb in). 1. Install the torque converter covers. 2. Install the lower air deflector 3. Lower the vehicle. 4. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5685 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5686 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5687 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5688 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5689 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5690 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5691 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5692 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5693 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5694 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5695 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5696 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5697 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5698 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5699 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5700 Auxiliary Power Outlet: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5701 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5702 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5703 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5704 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5705 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5706 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5707 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5708 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5709 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5710 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5711 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5712 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5713 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5714 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5715 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5716 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5717 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5718 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5719 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5720 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5721 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5722 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5723 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5724 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5725 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5726 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5727 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5728 Auxiliary Power Outlet: Connector Views Auxiliary Power Drop Connector (With RPO Code 9C1/9C3) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5729 Auxiliary Power Outlet Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 5730 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Diagram Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5731 Auxiliary Power Outlet: Service and Repair ACCESSORY POWER RECEPTACLE REPLACEMENT - FLOOR CONSOLE TOOLS REQUIRED J 42059 Cigar Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the power accessory receptacle fuse. 2. Remove the power accessory receptacle by placing one side of the "T" receptacle on of J 42059 into the tab window. Angle the other side into the opposite tab window. Pull the power accessory receptacle straight out. 3. If the standard method fails to remove the receptacle, use the following alternate method: 3.1. Insert a small grinding tool with a cutoff wheel into the receptacle. 3.2. Remove the plastic latches in the 3-mm (0.11-in) square windows. 3.3. Use J 42059 as directed above to remove the receptacle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5732 4. Remove J 42059 from the power accessory receptacle. 5. Disconnect the electrical connector from the receptacle 6. Using your index finger, pull out the receptacle retainer. INSTALLATION PROCEDURE 1. Align the power accessory receptacle retainer to the slot in the receptacle opening. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5733 2. Install the receptacle retainer by pressing the retainer into place until fully seated. 3. Connect the electrical connector to the power accessory receptacle. 4. Position the tabs on the receptacle to the retainer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5734 5. Install the receptacle into the front floor console, pressing the receptacle into place until fully seated. 6. Install the fuse to the power accessory receptacle. 7. Inspect the receptacle for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 5735 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block Fuse Block: Locations Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5744 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5745 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5746 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5747 Fuse Block: Locations Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5748 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5749 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5750 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5751 Fuse Block: Locations Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5752 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5753 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5754 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5755 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5756 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5757 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5758 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5759 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5760 Fuse Block: Locations Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5761 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5762 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5763 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5764 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5765 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5766 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5767 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 5768 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - SEO Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5771 Fuse Block - SEO Part 2 Junction Block - Left I/P - C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5772 Junction Block-Left I/P - C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5773 Junction Block-Left I/P - C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5774 Junction Block-Left I/P - C1 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5775 Junction Block-Left I/P - C1 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5776 Junction Block-Left I/P - C1 Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5777 Junction Block-Left I/P - C1 Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5778 Junction Block-Left I/P - C1 Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5779 Junction Block-Left I/P - C1 Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5780 Junction Block-Left I/P - C1 Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5781 Junction Block-Left I/P - C1 Part 10 Junction Block - Left I/P - C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5782 Junction Block-Left I/P - C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5783 Junction Block-Left I/P - C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5784 Junction Block-Left I/P - C2 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5785 Junction Block-Left I/P - C2 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5786 Junction Block-Left I/P - C2 Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5787 Junction Block-Left I/P - C2 Part 6 Junction Block - Right I/P - C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5788 Junction Block-Right I/P - C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5789 Junction Block-Right I/P - C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5790 Junction Block-Right I/P - C1 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5791 Junction Block-Right I/P - C1 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5792 Junction Block-Right I/P - C1 Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5793 Junction Block-Right I/P - C1 Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5794 Junction Block-Right I/P - C1 Part 7 Junction Block - Right I/P - C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5795 Junction Block-Right I/P - C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5796 Junction Block-Right I/P - C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5797 Junction Block-Right I/P - C2 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5798 Junction Block-Right I/P - C2 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5799 Junction Block-Right I/P - C2 Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5800 Junction Block-Right I/P - C2 Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5801 Junction Block-Right I/P - C2 Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 5802 Junction Block-Right I/P - C2 Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block Fuse Block: Application and ID Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5805 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5806 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5807 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5808 Fuse Block: Application and ID Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5809 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5810 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5811 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5812 Fuse Block: Application and ID Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5813 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5814 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5815 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5816 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5817 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5818 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5819 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5820 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5821 Fuse Block: Application and ID Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5822 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5823 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5824 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5825 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5826 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5827 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5828 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 5829 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the positive battery cables from the underhood fuse block terminals. 3. Remove the tape from the wiring harness at the base of the underhood fuse block base. 4. Release the underhood fuse block(s) clip retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 5832 5. Remove the fuse block(s) and wiring harness lifting up from the base and reposition from the base. 6. Remove the nuts from the underhood fuse block base. 7. Remove the underhood fuse block base from the shock tower. 8. Remove the underhood fuse block lower front terminal positive assurance retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 5833 9. Remove the plastic shields from the battery cable and buss bar terminals, using a small flat-bladed tool to release the clip retainer. 10. Remove the bolts from the buss bar jumper bar. 11. Remove the buss bar jumper bar from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 5834 12. Remove the fuses from the fuse block(s) to access the buss bar terminal release tabs. 13. Remove the buss bar(s) from the fuse block(s) using a terminal releasing tool, and pulling down and out on the buss bar. 14. Remove the buss bar(s) from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 5835 15. Release the clip retainers from the underhood fuse block(s) battery cable and buss bar terminals using a small flat-bladed tool. 16. Remove the underhood fuse block(s) battery cable and buss bar terminals from the fuse block by pulling down. 17. Remove the fuse block and lamp wiring harness from the vehicle, if required. INSTALLATION PROCEDURE 1. Install the underhood fuse block(s) battery cable and buss bar terminals to the fuse block(s) by sliding up into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 5836 2. Install the buss bar(s) to the fuse block(s) pressing into place until fully seated. 3. Position the underhood fuse block terminal positive assurance retainers to the fuse block(s). 4. Install the underhood fuse block(s) terminal positive assurance retainers pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 5837 5. Install the fuses to the fuse block(s) that were removed to access the buss bar terminal release tabs. 6. Install the buss bar jumper bar to the fuse block(s). NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the bolts to the buss bar jumper bar. Tighten Tighten the jumper bar bolts to 9 N.m (80 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 5838 8. Install the plastic shields to the battery cable and buss bar terminals pressing into place until fully seated. 9. Position the underhood fuse block(s) to the underhood fuse block base retaining locks. 10. Install the underhood fuse block(s) into the underhood fuse block base retaining locks pressing in until fully seated. 11. Install new tape to the wiring harness at the base of the underhood fuse block base. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 5839 12. Position the underhood fuse block base to the shock tower. 13. Install the nuts to the underhood fuse block base. Tighten Tighten the fuse block base nuts to 9 N.m (80 lb in). 14. Install the positive battery cables to the underhood fuse block. Tighten Tighten the positive battery cables nuts to 15 N.m (11 lb ft). 15. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 5840 Fuse Block: Service and Repair Instrument Panel Electrical Center / Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left I/P fuse block access hole cover. 3. Disconnect the outboard wiring harness connector C2 from the junction block. 4. Remove the connector position assurance (CPA) from the yellow inflatable restraint connector. Disconnect and reposition the yellow inflatable restraint connector for access to the bolts. 5. Remove the steering column filler. 6. Remove the I/P driver knee bolster. 7. Disconnect the inner wiring harness connector from the junction block. 8. Remove the junction block bolts. 9. Remove the junction block tab from the slot in the cross vehicle beam. Pull the junction block away from the I/P. 10. Remove the junction block. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 5841 1. Install the junction block tab to the slot in the cross vehicle beam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the junction block bolts. Tighten Tighten the junction block bolts to 10 N.m (89 lb in). 3. Connect the inner wiring harness connector to the junction block. Tighten Tighten the inner wiring harness connector bolt to 7 N.m (62 lb in). 4. Install the I/P driver knee bolster. 5. Install the steering column filler. 6. Connect the yellow inflatable restraint connector. Install the CPA. Attach the connector to the junction block. 7. Connect the outboard wiring harness connector C2 to the junction block. Tighten Tighten the body wiring harness connector bolt to 7 N.m (62 lb in). 8. Install the left I/P fuse block access hole cover. 9. Connect the negative battery cable. Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 5842 REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the RH instrument panel (IP) fuse block access opening cover. 3. Disconnect the body wiring harness from the junction block. 4. Open the IP compartment. Access the junction block bolt through the open IP compartment. Remove the junction block bolt. 5. Disengage the junction block tabs from the passenger knee bolster. Pull the junction block away from the IP. 6. Disconnect the wiring harnesses from the junction block. 7. Remove the junction block. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 5843 1. Connect the body wiring harnesses to the junction block. Tighten Tighten the body wiring harness connector bolts to 7 N.m (62 lb in). 2. Install the junction block tabs to the passenger knee bolster. 3. Install the junction block bolt. Tighten Tighten the junction block bolt to 10 N.m (89 lb in). 4. Close the IP compartment. 5. Connect the body wiring harness to the junction block. 6. Install the RH IP fuse block access opening cover. 7. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 5844 Fuse Block: Service and Repair Junction Block Replacement - Accessory Wiring JUNCTION BLOCK REPLACEMENT - ACCESSORY WIRING REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left instrument panel (I/P) insulator. 3. Remove the screws from the accessory wiring junction block. 4. Adjust the junction block for access. 5. Remove the circuit breakers (4) and the relays from the junction block as required. 6. If necessary remove the junction block from the bracket assembly. INSTALLATION PROCEDURE 1. If necessary install the junction block to the bracket assembly. 2. Install the circuit breakers (4) and the relays to the junction block as required. 3. Position the junction block to the I/P carrier. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the junction block screws. Tighten Tighten the screws to 10 N.m (89 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 5845 5. Install the left I/P insulator. 6. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5850 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5851 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5852 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5853 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5854 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 5855 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Multiple Junction Connector: Customer Interest BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 5864 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Multiple Junction Connector: All Technical Service Bulletins BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 5870 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 Multiple Junction Connector: Diagrams C101 - C126 C101 Inline Connector C101 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5873 Inline Connector C101 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5874 Inline Connector C101 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5875 Inline Connector C102 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5876 Inline Connector C102 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5877 Inline Connector C106 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5878 Inline Connector C106 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5879 Inline Connector C106 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5880 Inline Connector C110 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5881 Inline Connector C110 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5882 Inline Connector C112 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5883 Inline Connector C112 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5884 Inline Connector C113 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5885 Inline Connector C113 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5886 Inline Connector C122 Part 1 Inline Connector C122 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5887 Inline Connector C123 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5888 Inline Connector C125 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5889 Inline Connector C126 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5890 Multiple Junction Connector: Diagrams C201 - C299B Inline Connector C201 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5891 Inline Connector C201 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5892 Inline Connector C201 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5893 Inline Connector C201 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5894 Inline Connector C209 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5895 Inline Connector C209A Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5896 Inline Connector C209B Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5897 Inline Connector C210 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5898 Inline Connector C210 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5899 Inline Connector C216 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5900 Inline Connector C217 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5901 Inline Connector C218 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5902 Inline Connector C225 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5903 Inline Connector C240 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5904 Inline Connector C255 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5905 Inline Connector C255A Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5906 Inline Connector C255B Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5907 Inline Connector C297 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5908 Inline Connector C297 Part 2 Inline Connector C299 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5909 Inline Connector C299 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5910 Inline Connector C299A Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5911 Inline Connector C299B Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5912 Multiple Junction Connector: Diagrams C301 - C392 C301 Inline Connector C301 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5913 Inline Connector C301 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5914 Inline Connector C301 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5915 Inline Connector C301 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5916 Inline Connector C301 Part 5 C302 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5917 Inline Connector C302 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5918 Inline Connector C302 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5919 Inline Connector C302 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5920 Inline Connector C302 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5921 Inline Connector C306 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5922 Inline Connector C308 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5923 Inline Connector C311 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5924 Inline Connector C312 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5925 Inline Connector C315 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5926 Inline Connector C315 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5927 Inline Connector C317 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5928 Inline Connector C355 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5929 Inline Connector C356 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5930 Inline Connector C356 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5931 Inline Connector C373 Part 1 Inline Connector C373 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5932 Inline Connector C392 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5933 Inline Connector C392 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5934 Multiple Junction Connector: Diagrams C400 - C901 Inline Connector C400 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5935 Inline Connector C405 (1A-1D) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5936 Inline Connector C405 (3A-3H) Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5937 Inline Connector C405 (3A-3H) Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5938 Inline Connector C409 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5939 Inline Connector C430 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5940 Inline Connector C435 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5941 Inline Connector C440 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5942 Inline Connector C901 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5943 Multiple Junction Connector: Diagrams SP205 Splice Pack - SP205 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 5944 Splice Pack - SP205 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block Relay Box: Locations Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5950 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5951 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5952 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5953 Relay Box: Locations Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5954 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5955 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5956 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5957 Relay Box: Locations Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5958 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5959 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5960 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5961 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5962 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5963 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5964 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5965 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5966 Relay Box: Locations Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5967 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5968 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5969 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5970 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5971 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5972 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5973 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 5974 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block Relay Box: Application and ID Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5977 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5978 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5979 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5980 Relay Box: Application and ID Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5981 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5982 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5983 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5984 Relay Box: Application and ID Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5985 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5986 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5987 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5988 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5989 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5990 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5991 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5992 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5993 Relay Box: Application and ID Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5994 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5995 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5996 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5997 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5998 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 5999 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6000 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6001 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the positive battery cables from the underhood fuse block terminals. 3. Remove the tape from the wiring harness at the base of the underhood fuse block base. 4. Release the underhood fuse block(s) clip retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6004 5. Remove the fuse block(s) and wiring harness lifting up from the base and reposition from the base. 6. Remove the nuts from the underhood fuse block base. 7. Remove the underhood fuse block base from the shock tower. 8. Remove the underhood fuse block lower front terminal positive assurance retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6005 9. Remove the plastic shields from the battery cable and buss bar terminals, using a small flat-bladed tool to release the clip retainer. 10. Remove the bolts from the buss bar jumper bar. 11. Remove the buss bar jumper bar from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6006 12. Remove the fuses from the fuse block(s) to access the buss bar terminal release tabs. 13. Remove the buss bar(s) from the fuse block(s) using a terminal releasing tool, and pulling down and out on the buss bar. 14. Remove the buss bar(s) from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6007 15. Release the clip retainers from the underhood fuse block(s) battery cable and buss bar terminals using a small flat-bladed tool. 16. Remove the underhood fuse block(s) battery cable and buss bar terminals from the fuse block by pulling down. 17. Remove the fuse block and lamp wiring harness from the vehicle, if required. INSTALLATION PROCEDURE 1. Install the underhood fuse block(s) battery cable and buss bar terminals to the fuse block(s) by sliding up into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6008 2. Install the buss bar(s) to the fuse block(s) pressing into place until fully seated. 3. Position the underhood fuse block terminal positive assurance retainers to the fuse block(s). 4. Install the underhood fuse block(s) terminal positive assurance retainers pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6009 5. Install the fuses to the fuse block(s) that were removed to access the buss bar terminal release tabs. 6. Install the buss bar jumper bar to the fuse block(s). NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the bolts to the buss bar jumper bar. Tighten Tighten the jumper bar bolts to 9 N.m (80 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6010 8. Install the plastic shields to the battery cable and buss bar terminals pressing into place until fully seated. 9. Position the underhood fuse block(s) to the underhood fuse block base retaining locks. 10. Install the underhood fuse block(s) into the underhood fuse block base retaining locks pressing in until fully seated. 11. Install new tape to the wiring harness at the base of the underhood fuse block base. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6011 12. Position the underhood fuse block base to the shock tower. 13. Install the nuts to the underhood fuse block base. Tighten Tighten the fuse block base nuts to 9 N.m (80 lb in). 14. Install the positive battery cables to the underhood fuse block. Tighten Tighten the positive battery cables nuts to 15 N.m (11 lb ft). 15. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6012 Relay Box: Service and Repair Instrument Panel Electrical Center / Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left I/P fuse block access hole cover. 3. Disconnect the outboard wiring harness connector C2 from the junction block. 4. Remove the connector position assurance (CPA) from the yellow inflatable restraint connector. Disconnect and reposition the yellow inflatable restraint connector for access to the bolts. 5. Remove the steering column filler. 6. Remove the I/P driver knee bolster. 7. Disconnect the inner wiring harness connector from the junction block. 8. Remove the junction block bolts. 9. Remove the junction block tab from the slot in the cross vehicle beam. Pull the junction block away from the I/P. 10. Remove the junction block. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6013 1. Install the junction block tab to the slot in the cross vehicle beam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the junction block bolts. Tighten Tighten the junction block bolts to 10 N.m (89 lb in). 3. Connect the inner wiring harness connector to the junction block. Tighten Tighten the inner wiring harness connector bolt to 7 N.m (62 lb in). 4. Install the I/P driver knee bolster. 5. Install the steering column filler. 6. Connect the yellow inflatable restraint connector. Install the CPA. Attach the connector to the junction block. 7. Connect the outboard wiring harness connector C2 to the junction block. Tighten Tighten the body wiring harness connector bolt to 7 N.m (62 lb in). 8. Install the left I/P fuse block access hole cover. 9. Connect the negative battery cable. Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6014 REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the RH instrument panel (IP) fuse block access opening cover. 3. Disconnect the body wiring harness from the junction block. 4. Open the IP compartment. Access the junction block bolt through the open IP compartment. Remove the junction block bolt. 5. Disengage the junction block tabs from the passenger knee bolster. Pull the junction block away from the IP. 6. Disconnect the wiring harnesses from the junction block. 7. Remove the junction block. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6015 1. Connect the body wiring harnesses to the junction block. Tighten Tighten the body wiring harness connector bolts to 7 N.m (62 lb in). 2. Install the junction block tabs to the passenger knee bolster. 3. Install the junction block bolt. Tighten Tighten the junction block bolt to 10 N.m (89 lb in). 4. Close the IP compartment. 5. Connect the body wiring harness to the junction block. 6. Install the RH IP fuse block access opening cover. 7. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6016 Relay Box: Service and Repair Junction Block Replacement - Accessory Wiring JUNCTION BLOCK REPLACEMENT - ACCESSORY WIRING REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left instrument panel (I/P) insulator. 3. Remove the screws from the accessory wiring junction block. 4. Adjust the junction block for access. 5. Remove the circuit breakers (4) and the relays from the junction block as required. 6. If necessary remove the junction block from the bracket assembly. INSTALLATION PROCEDURE 1. If necessary install the junction block to the bracket assembly. 2. Install the circuit breakers (4) and the relays to the junction block as required. 3. Position the junction block to the I/P carrier. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the junction block screws. Tighten Tighten the screws to 10 N.m (89 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6017 5. Install the left I/P insulator. 6. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block Relay Box: Locations Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6022 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6023 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6024 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6025 Relay Box: Locations Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6026 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6027 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6028 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6029 Relay Box: Locations Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6030 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6031 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6032 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6033 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6034 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6035 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6036 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6037 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6038 Relay Box: Locations Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6039 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6040 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6041 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6042 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6043 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6044 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6045 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6046 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block Relay Box: Application and ID Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6049 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6050 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6051 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6052 Relay Box: Application and ID Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6053 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6054 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6055 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6056 Relay Box: Application and ID Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6057 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6058 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6059 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6060 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6061 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6062 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6063 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6064 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6065 Relay Box: Application and ID Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6066 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6067 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6068 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6069 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6070 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6071 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6072 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6073 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the positive battery cables from the underhood fuse block terminals. 3. Remove the tape from the wiring harness at the base of the underhood fuse block base. 4. Release the underhood fuse block(s) clip retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6076 5. Remove the fuse block(s) and wiring harness lifting up from the base and reposition from the base. 6. Remove the nuts from the underhood fuse block base. 7. Remove the underhood fuse block base from the shock tower. 8. Remove the underhood fuse block lower front terminal positive assurance retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6077 9. Remove the plastic shields from the battery cable and buss bar terminals, using a small flat-bladed tool to release the clip retainer. 10. Remove the bolts from the buss bar jumper bar. 11. Remove the buss bar jumper bar from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6078 12. Remove the fuses from the fuse block(s) to access the buss bar terminal release tabs. 13. Remove the buss bar(s) from the fuse block(s) using a terminal releasing tool, and pulling down and out on the buss bar. 14. Remove the buss bar(s) from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6079 15. Release the clip retainers from the underhood fuse block(s) battery cable and buss bar terminals using a small flat-bladed tool. 16. Remove the underhood fuse block(s) battery cable and buss bar terminals from the fuse block by pulling down. 17. Remove the fuse block and lamp wiring harness from the vehicle, if required. INSTALLATION PROCEDURE 1. Install the underhood fuse block(s) battery cable and buss bar terminals to the fuse block(s) by sliding up into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6080 2. Install the buss bar(s) to the fuse block(s) pressing into place until fully seated. 3. Position the underhood fuse block terminal positive assurance retainers to the fuse block(s). 4. Install the underhood fuse block(s) terminal positive assurance retainers pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6081 5. Install the fuses to the fuse block(s) that were removed to access the buss bar terminal release tabs. 6. Install the buss bar jumper bar to the fuse block(s). NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the bolts to the buss bar jumper bar. Tighten Tighten the jumper bar bolts to 9 N.m (80 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6082 8. Install the plastic shields to the battery cable and buss bar terminals pressing into place until fully seated. 9. Position the underhood fuse block(s) to the underhood fuse block base retaining locks. 10. Install the underhood fuse block(s) into the underhood fuse block base retaining locks pressing in until fully seated. 11. Install new tape to the wiring harness at the base of the underhood fuse block base. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6083 12. Position the underhood fuse block base to the shock tower. 13. Install the nuts to the underhood fuse block base. Tighten Tighten the fuse block base nuts to 9 N.m (80 lb in). 14. Install the positive battery cables to the underhood fuse block. Tighten Tighten the positive battery cables nuts to 15 N.m (11 lb ft). 15. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6084 Relay Box: Service and Repair Instrument Panel Electrical Center / Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left I/P fuse block access hole cover. 3. Disconnect the outboard wiring harness connector C2 from the junction block. 4. Remove the connector position assurance (CPA) from the yellow inflatable restraint connector. Disconnect and reposition the yellow inflatable restraint connector for access to the bolts. 5. Remove the steering column filler. 6. Remove the I/P driver knee bolster. 7. Disconnect the inner wiring harness connector from the junction block. 8. Remove the junction block bolts. 9. Remove the junction block tab from the slot in the cross vehicle beam. Pull the junction block away from the I/P. 10. Remove the junction block. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6085 1. Install the junction block tab to the slot in the cross vehicle beam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the junction block bolts. Tighten Tighten the junction block bolts to 10 N.m (89 lb in). 3. Connect the inner wiring harness connector to the junction block. Tighten Tighten the inner wiring harness connector bolt to 7 N.m (62 lb in). 4. Install the I/P driver knee bolster. 5. Install the steering column filler. 6. Connect the yellow inflatable restraint connector. Install the CPA. Attach the connector to the junction block. 7. Connect the outboard wiring harness connector C2 to the junction block. Tighten Tighten the body wiring harness connector bolt to 7 N.m (62 lb in). 8. Install the left I/P fuse block access hole cover. 9. Connect the negative battery cable. Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6086 REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the RH instrument panel (IP) fuse block access opening cover. 3. Disconnect the body wiring harness from the junction block. 4. Open the IP compartment. Access the junction block bolt through the open IP compartment. Remove the junction block bolt. 5. Disengage the junction block tabs from the passenger knee bolster. Pull the junction block away from the IP. 6. Disconnect the wiring harnesses from the junction block. 7. Remove the junction block. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6087 1. Connect the body wiring harnesses to the junction block. Tighten Tighten the body wiring harness connector bolts to 7 N.m (62 lb in). 2. Install the junction block tabs to the passenger knee bolster. 3. Install the junction block bolt. Tighten Tighten the junction block bolt to 10 N.m (89 lb in). 4. Close the IP compartment. 5. Connect the body wiring harness to the junction block. 6. Install the RH IP fuse block access opening cover. 7. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6088 Relay Box: Service and Repair Junction Block Replacement - Accessory Wiring JUNCTION BLOCK REPLACEMENT - ACCESSORY WIRING REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left instrument panel (I/P) insulator. 3. Remove the screws from the accessory wiring junction block. 4. Adjust the junction block for access. 5. Remove the circuit breakers (4) and the relays from the junction block as required. 6. If necessary remove the junction block from the bracket assembly. INSTALLATION PROCEDURE 1. If necessary install the junction block to the bracket assembly. 2. Install the circuit breakers (4) and the relays to the junction block as required. 3. Position the junction block to the I/P carrier. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the junction block screws. Tighten Tighten the screws to 10 N.m (89 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6089 5. Install the left I/P insulator. 6. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6098 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6099 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6100 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6106 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6107 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6108 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6113 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6114 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6115 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6116 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6117 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6118 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 6123 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6129 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6130 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6131 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6132 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6133 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6134 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 6139 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6145 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6146 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6147 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6148 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6149 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6150 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6151 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6152 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6153 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6154 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6155 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6156 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6157 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6158 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6159 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6160 Auxiliary Power Outlet: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6161 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6162 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6163 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6164 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6165 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6166 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6167 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6168 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6169 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6170 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6171 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6172 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6173 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6174 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6175 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6176 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6177 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6178 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6179 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6180 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6181 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6182 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6183 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6184 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6185 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6186 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6187 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6188 Auxiliary Power Outlet: Connector Views Auxiliary Power Drop Connector (With RPO Code 9C1/9C3) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6189 Auxiliary Power Outlet Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Diagram Information and Instructions > Page 6190 Auxiliary Power Outlet: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Diagram Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6191 Auxiliary Power Outlet: Service and Repair ACCESSORY POWER RECEPTACLE REPLACEMENT - FLOOR CONSOLE TOOLS REQUIRED J 42059 Cigar Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the power accessory receptacle fuse. 2. Remove the power accessory receptacle by placing one side of the "T" receptacle on of J 42059 into the tab window. Angle the other side into the opposite tab window. Pull the power accessory receptacle straight out. 3. If the standard method fails to remove the receptacle, use the following alternate method: 3.1. Insert a small grinding tool with a cutoff wheel into the receptacle. 3.2. Remove the plastic latches in the 3-mm (0.11-in) square windows. 3.3. Use J 42059 as directed above to remove the receptacle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6192 4. Remove J 42059 from the power accessory receptacle. 5. Disconnect the electrical connector from the receptacle 6. Using your index finger, pull out the receptacle retainer. INSTALLATION PROCEDURE 1. Align the power accessory receptacle retainer to the slot in the receptacle opening. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6193 2. Install the receptacle retainer by pressing the retainer into place until fully seated. 3. Connect the electrical connector to the power accessory receptacle. 4. Position the tabs on the receptacle to the retainer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6194 5. Install the receptacle into the front floor console, pressing the receptacle into place until fully seated. 6. Install the fuse to the power accessory receptacle. 7. Inspect the receptacle for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams > Page 6195 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Electrical - Aftermarket Fuse Warning Fuse: Technical Service Bulletins Electrical - Aftermarket Fuse Warning Bulletin No.: 07-08-45-002 Date: September 05, 2007 ADVANCED SERVICE INFORMATION Subject: Service Alert: Concerns With Aftermarket Fuses in GM Vehicles Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X Concerns with Harbor Freight Tools "Storehouse" Branded Blade Type Fuses General Motors has become aware of a fuse recall by Harbor Freight Tools/Storehouse for a variety of aftermarket fuses. In two cases, these fuses have not provided protection for the wiring system of the vehicles they were customer installed in. Upon testing the 15 amp version, it was found that the fuse still would not "open" when shorted directly across the battery terminals. How to Identify These Fuses Packed in a 120 piece set, the fuse has a translucent, hard plastic, blue body with the amperage stamped into the top. There are no white painted numbers on the fuse to indicate amperage. There are no identifying marks on the fuse to tell who is making it. The fuses are known to be distributed by Harbor Freight Tools but there may be other marketers, and packaging of this style of fuse. It would be prudent to replace these fuses if found in a customers vehicle. Likewise, if wiring overheating is found you should check the fuse panel for the presence of this style of fuse. All GM dealers should use genuine GM fuses on the vehicles they service. You should also encourage the use of GM fuses to your customers to assure they are getting the required electrical system protection. GM has no knowledge of any concerns with other aftermarket fuses. If additional information becomes available, this bulletin will be updated. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block Fuse Block: Locations Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6204 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6205 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6206 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6207 Fuse Block: Locations Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6208 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6209 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6210 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6211 Fuse Block: Locations Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6212 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6213 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6214 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6215 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6216 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6217 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6218 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6219 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6220 Fuse Block: Locations Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6221 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6222 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6223 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6224 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6225 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6226 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6227 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Left I/P - Junction Block > Page 6228 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views Fuse Block: Connector Views Fuse Block - SEO Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6231 Fuse Block - SEO Part 2 Junction Block - Left I/P - C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6232 Junction Block-Left I/P - C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6233 Junction Block-Left I/P - C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6234 Junction Block-Left I/P - C1 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6235 Junction Block-Left I/P - C1 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6236 Junction Block-Left I/P - C1 Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6237 Junction Block-Left I/P - C1 Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6238 Junction Block-Left I/P - C1 Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6239 Junction Block-Left I/P - C1 Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6240 Junction Block-Left I/P - C1 Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6241 Junction Block-Left I/P - C1 Part 10 Junction Block - Left I/P - C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6242 Junction Block-Left I/P - C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6243 Junction Block-Left I/P - C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6244 Junction Block-Left I/P - C2 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6245 Junction Block-Left I/P - C2 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6246 Junction Block-Left I/P - C2 Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6247 Junction Block-Left I/P - C2 Part 6 Junction Block - Right I/P - C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6248 Junction Block-Right I/P - C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6249 Junction Block-Right I/P - C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6250 Junction Block-Right I/P - C1 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6251 Junction Block-Right I/P - C1 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6252 Junction Block-Right I/P - C1 Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6253 Junction Block-Right I/P - C1 Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6254 Junction Block-Right I/P - C1 Part 7 Junction Block - Right I/P - C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6255 Junction Block-Right I/P - C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6256 Junction Block-Right I/P - C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6257 Junction Block-Right I/P - C2 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6258 Junction Block-Right I/P - C2 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6259 Junction Block-Right I/P - C2 Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6260 Junction Block-Right I/P - C2 Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6261 Junction Block-Right I/P - C2 Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Connector Views > Page 6262 Junction Block-Right I/P - C2 Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block Fuse Block: Application and ID Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6265 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6266 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6267 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6268 Fuse Block: Application and ID Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6269 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6270 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6271 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6272 Fuse Block: Application and ID Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6273 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6274 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6275 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6276 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6277 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6278 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6279 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6280 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6281 Fuse Block: Application and ID Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6282 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6283 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6284 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6285 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6286 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6287 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6288 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Application and ID > Left I/P - Junction Block > Page 6289 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Fuse Block: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the positive battery cables from the underhood fuse block terminals. 3. Remove the tape from the wiring harness at the base of the underhood fuse block base. 4. Release the underhood fuse block(s) clip retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6292 5. Remove the fuse block(s) and wiring harness lifting up from the base and reposition from the base. 6. Remove the nuts from the underhood fuse block base. 7. Remove the underhood fuse block base from the shock tower. 8. Remove the underhood fuse block lower front terminal positive assurance retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6293 9. Remove the plastic shields from the battery cable and buss bar terminals, using a small flat-bladed tool to release the clip retainer. 10. Remove the bolts from the buss bar jumper bar. 11. Remove the buss bar jumper bar from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6294 12. Remove the fuses from the fuse block(s) to access the buss bar terminal release tabs. 13. Remove the buss bar(s) from the fuse block(s) using a terminal releasing tool, and pulling down and out on the buss bar. 14. Remove the buss bar(s) from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6295 15. Release the clip retainers from the underhood fuse block(s) battery cable and buss bar terminals using a small flat-bladed tool. 16. Remove the underhood fuse block(s) battery cable and buss bar terminals from the fuse block by pulling down. 17. Remove the fuse block and lamp wiring harness from the vehicle, if required. INSTALLATION PROCEDURE 1. Install the underhood fuse block(s) battery cable and buss bar terminals to the fuse block(s) by sliding up into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6296 2. Install the buss bar(s) to the fuse block(s) pressing into place until fully seated. 3. Position the underhood fuse block terminal positive assurance retainers to the fuse block(s). 4. Install the underhood fuse block(s) terminal positive assurance retainers pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6297 5. Install the fuses to the fuse block(s) that were removed to access the buss bar terminal release tabs. 6. Install the buss bar jumper bar to the fuse block(s). NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the bolts to the buss bar jumper bar. Tighten Tighten the jumper bar bolts to 9 N.m (80 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6298 8. Install the plastic shields to the battery cable and buss bar terminals pressing into place until fully seated. 9. Position the underhood fuse block(s) to the underhood fuse block base retaining locks. 10. Install the underhood fuse block(s) into the underhood fuse block base retaining locks pressing in until fully seated. 11. Install new tape to the wiring harness at the base of the underhood fuse block base. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6299 12. Position the underhood fuse block base to the shock tower. 13. Install the nuts to the underhood fuse block base. Tighten Tighten the fuse block base nuts to 9 N.m (80 lb in). 14. Install the positive battery cables to the underhood fuse block. Tighten Tighten the positive battery cables nuts to 15 N.m (11 lb ft). 15. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6300 Fuse Block: Service and Repair Instrument Panel Electrical Center / Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left I/P fuse block access hole cover. 3. Disconnect the outboard wiring harness connector C2 from the junction block. 4. Remove the connector position assurance (CPA) from the yellow inflatable restraint connector. Disconnect and reposition the yellow inflatable restraint connector for access to the bolts. 5. Remove the steering column filler. 6. Remove the I/P driver knee bolster. 7. Disconnect the inner wiring harness connector from the junction block. 8. Remove the junction block bolts. 9. Remove the junction block tab from the slot in the cross vehicle beam. Pull the junction block away from the I/P. 10. Remove the junction block. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6301 1. Install the junction block tab to the slot in the cross vehicle beam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the junction block bolts. Tighten Tighten the junction block bolts to 10 N.m (89 lb in). 3. Connect the inner wiring harness connector to the junction block. Tighten Tighten the inner wiring harness connector bolt to 7 N.m (62 lb in). 4. Install the I/P driver knee bolster. 5. Install the steering column filler. 6. Connect the yellow inflatable restraint connector. Install the CPA. Attach the connector to the junction block. 7. Connect the outboard wiring harness connector C2 to the junction block. Tighten Tighten the body wiring harness connector bolt to 7 N.m (62 lb in). 8. Install the left I/P fuse block access hole cover. 9. Connect the negative battery cable. Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6302 REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the RH instrument panel (IP) fuse block access opening cover. 3. Disconnect the body wiring harness from the junction block. 4. Open the IP compartment. Access the junction block bolt through the open IP compartment. Remove the junction block bolt. 5. Disengage the junction block tabs from the passenger knee bolster. Pull the junction block away from the IP. 6. Disconnect the wiring harnesses from the junction block. 7. Remove the junction block. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6303 1. Connect the body wiring harnesses to the junction block. Tighten Tighten the body wiring harness connector bolts to 7 N.m (62 lb in). 2. Install the junction block tabs to the passenger knee bolster. 3. Install the junction block bolt. Tighten Tighten the junction block bolt to 10 N.m (89 lb in). 4. Close the IP compartment. 5. Connect the body wiring harness to the junction block. 6. Install the RH IP fuse block access opening cover. 7. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6304 Fuse Block: Service and Repair Junction Block Replacement - Accessory Wiring JUNCTION BLOCK REPLACEMENT - ACCESSORY WIRING REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left instrument panel (I/P) insulator. 3. Remove the screws from the accessory wiring junction block. 4. Adjust the junction block for access. 5. Remove the circuit breakers (4) and the relays from the junction block as required. 6. If necessary remove the junction block from the bracket assembly. INSTALLATION PROCEDURE 1. If necessary install the junction block to the bracket assembly. 2. Install the circuit breakers (4) and the relays to the junction block as required. 3. Position the junction block to the I/P carrier. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the junction block screws. Tighten Tighten the screws to 10 N.m (89 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6305 5. Install the left I/P insulator. 6. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair Grounding Point: Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6310 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6311 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6312 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6313 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6314 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Grounding Point > Component Information > Technical Service Bulletins > Electrical - Information For Electrical Ground Repair > Page 6315 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 04-08-47-003 > Aug > 04 > BCM Security Lamp ON/No Crank/DTC's Set Multiple Junction Connector: Customer Interest BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 04-08-47-003 > Aug > 04 > BCM Security Lamp ON/No Crank/DTC's Set > Page 6324 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Multiple Junction Connector: All Technical Service Bulletins BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 6330 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 Multiple Junction Connector: Diagrams C101 - C126 C101 Inline Connector C101 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6333 Inline Connector C101 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6334 Inline Connector C101 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6335 Inline Connector C102 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6336 Inline Connector C102 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6337 Inline Connector C106 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6338 Inline Connector C106 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6339 Inline Connector C106 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6340 Inline Connector C110 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6341 Inline Connector C110 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6342 Inline Connector C112 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6343 Inline Connector C112 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6344 Inline Connector C113 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6345 Inline Connector C113 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6346 Inline Connector C122 Part 1 Inline Connector C122 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6347 Inline Connector C123 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6348 Inline Connector C125 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6349 Inline Connector C126 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6350 Multiple Junction Connector: Diagrams C201 - C299B Inline Connector C201 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6351 Inline Connector C201 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6352 Inline Connector C201 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6353 Inline Connector C201 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6354 Inline Connector C209 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6355 Inline Connector C209A Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6356 Inline Connector C209B Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6357 Inline Connector C210 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6358 Inline Connector C210 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6359 Inline Connector C216 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6360 Inline Connector C217 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6361 Inline Connector C218 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6362 Inline Connector C225 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6363 Inline Connector C240 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6364 Inline Connector C255 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6365 Inline Connector C255A Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6366 Inline Connector C255B Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6367 Inline Connector C297 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6368 Inline Connector C297 Part 2 Inline Connector C299 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6369 Inline Connector C299 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6370 Inline Connector C299A Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6371 Inline Connector C299B Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6372 Multiple Junction Connector: Diagrams C301 - C392 C301 Inline Connector C301 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6373 Inline Connector C301 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6374 Inline Connector C301 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6375 Inline Connector C301 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6376 Inline Connector C301 Part 5 C302 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6377 Inline Connector C302 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6378 Inline Connector C302 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6379 Inline Connector C302 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6380 Inline Connector C302 Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6381 Inline Connector C306 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6382 Inline Connector C308 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6383 Inline Connector C311 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6384 Inline Connector C312 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6385 Inline Connector C315 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6386 Inline Connector C315 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6387 Inline Connector C317 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6388 Inline Connector C355 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6389 Inline Connector C356 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6390 Inline Connector C356 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6391 Inline Connector C373 Part 1 Inline Connector C373 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6392 Inline Connector C392 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6393 Inline Connector C392 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6394 Multiple Junction Connector: Diagrams C400 - C901 Inline Connector C400 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6395 Inline Connector C405 (1A-1D) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6396 Inline Connector C405 (3A-3H) Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6397 Inline Connector C405 (3A-3H) Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6398 Inline Connector C409 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6399 Inline Connector C430 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6400 Inline Connector C435 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6401 Inline Connector C440 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6402 Inline Connector C901 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6403 Multiple Junction Connector: Diagrams SP205 Splice Pack - SP205 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Diagrams > C101 - C126 > Page 6404 Splice Pack - SP205 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block Relay Box: Locations Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6410 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6411 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6412 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6413 Relay Box: Locations Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6414 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6415 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6416 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6417 Relay Box: Locations Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6418 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6419 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6420 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6421 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6422 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6423 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6424 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6425 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6426 Relay Box: Locations Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6427 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6428 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6429 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6430 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6431 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6432 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6433 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6434 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block Relay Box: Application and ID Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6437 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6438 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6439 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6440 Relay Box: Application and ID Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6441 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6442 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6443 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6444 Relay Box: Application and ID Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6445 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6446 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6447 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6448 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6449 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6450 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6451 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6452 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6453 Relay Box: Application and ID Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6454 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6455 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6456 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6457 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6458 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6459 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6460 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6461 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the positive battery cables from the underhood fuse block terminals. 3. Remove the tape from the wiring harness at the base of the underhood fuse block base. 4. Release the underhood fuse block(s) clip retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6464 5. Remove the fuse block(s) and wiring harness lifting up from the base and reposition from the base. 6. Remove the nuts from the underhood fuse block base. 7. Remove the underhood fuse block base from the shock tower. 8. Remove the underhood fuse block lower front terminal positive assurance retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6465 9. Remove the plastic shields from the battery cable and buss bar terminals, using a small flat-bladed tool to release the clip retainer. 10. Remove the bolts from the buss bar jumper bar. 11. Remove the buss bar jumper bar from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6466 12. Remove the fuses from the fuse block(s) to access the buss bar terminal release tabs. 13. Remove the buss bar(s) from the fuse block(s) using a terminal releasing tool, and pulling down and out on the buss bar. 14. Remove the buss bar(s) from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6467 15. Release the clip retainers from the underhood fuse block(s) battery cable and buss bar terminals using a small flat-bladed tool. 16. Remove the underhood fuse block(s) battery cable and buss bar terminals from the fuse block by pulling down. 17. Remove the fuse block and lamp wiring harness from the vehicle, if required. INSTALLATION PROCEDURE 1. Install the underhood fuse block(s) battery cable and buss bar terminals to the fuse block(s) by sliding up into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6468 2. Install the buss bar(s) to the fuse block(s) pressing into place until fully seated. 3. Position the underhood fuse block terminal positive assurance retainers to the fuse block(s). 4. Install the underhood fuse block(s) terminal positive assurance retainers pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6469 5. Install the fuses to the fuse block(s) that were removed to access the buss bar terminal release tabs. 6. Install the buss bar jumper bar to the fuse block(s). NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the bolts to the buss bar jumper bar. Tighten Tighten the jumper bar bolts to 9 N.m (80 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6470 8. Install the plastic shields to the battery cable and buss bar terminals pressing into place until fully seated. 9. Position the underhood fuse block(s) to the underhood fuse block base retaining locks. 10. Install the underhood fuse block(s) into the underhood fuse block base retaining locks pressing in until fully seated. 11. Install new tape to the wiring harness at the base of the underhood fuse block base. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6471 12. Position the underhood fuse block base to the shock tower. 13. Install the nuts to the underhood fuse block base. Tighten Tighten the fuse block base nuts to 9 N.m (80 lb in). 14. Install the positive battery cables to the underhood fuse block. Tighten Tighten the positive battery cables nuts to 15 N.m (11 lb ft). 15. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6472 Relay Box: Service and Repair Instrument Panel Electrical Center / Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left I/P fuse block access hole cover. 3. Disconnect the outboard wiring harness connector C2 from the junction block. 4. Remove the connector position assurance (CPA) from the yellow inflatable restraint connector. Disconnect and reposition the yellow inflatable restraint connector for access to the bolts. 5. Remove the steering column filler. 6. Remove the I/P driver knee bolster. 7. Disconnect the inner wiring harness connector from the junction block. 8. Remove the junction block bolts. 9. Remove the junction block tab from the slot in the cross vehicle beam. Pull the junction block away from the I/P. 10. Remove the junction block. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6473 1. Install the junction block tab to the slot in the cross vehicle beam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the junction block bolts. Tighten Tighten the junction block bolts to 10 N.m (89 lb in). 3. Connect the inner wiring harness connector to the junction block. Tighten Tighten the inner wiring harness connector bolt to 7 N.m (62 lb in). 4. Install the I/P driver knee bolster. 5. Install the steering column filler. 6. Connect the yellow inflatable restraint connector. Install the CPA. Attach the connector to the junction block. 7. Connect the outboard wiring harness connector C2 to the junction block. Tighten Tighten the body wiring harness connector bolt to 7 N.m (62 lb in). 8. Install the left I/P fuse block access hole cover. 9. Connect the negative battery cable. Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6474 REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the RH instrument panel (IP) fuse block access opening cover. 3. Disconnect the body wiring harness from the junction block. 4. Open the IP compartment. Access the junction block bolt through the open IP compartment. Remove the junction block bolt. 5. Disengage the junction block tabs from the passenger knee bolster. Pull the junction block away from the IP. 6. Disconnect the wiring harnesses from the junction block. 7. Remove the junction block. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6475 1. Connect the body wiring harnesses to the junction block. Tighten Tighten the body wiring harness connector bolts to 7 N.m (62 lb in). 2. Install the junction block tabs to the passenger knee bolster. 3. Install the junction block bolt. Tighten Tighten the junction block bolt to 10 N.m (89 lb in). 4. Close the IP compartment. 5. Connect the body wiring harness to the junction block. 6. Install the RH IP fuse block access opening cover. 7. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6476 Relay Box: Service and Repair Junction Block Replacement - Accessory Wiring JUNCTION BLOCK REPLACEMENT - ACCESSORY WIRING REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left instrument panel (I/P) insulator. 3. Remove the screws from the accessory wiring junction block. 4. Adjust the junction block for access. 5. Remove the circuit breakers (4) and the relays from the junction block as required. 6. If necessary remove the junction block from the bracket assembly. INSTALLATION PROCEDURE 1. If necessary install the junction block to the bracket assembly. 2. Install the circuit breakers (4) and the relays to the junction block as required. 3. Position the junction block to the I/P carrier. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the junction block screws. Tighten Tighten the screws to 10 N.m (89 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6477 5. Install the left I/P insulator. 6. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block Relay Box: Locations Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6482 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6483 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6484 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6485 Relay Box: Locations Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6486 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6487 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6488 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6489 Relay Box: Locations Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6490 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6491 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6492 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6493 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6494 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6495 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6496 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6497 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6498 Relay Box: Locations Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6499 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6500 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6501 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6502 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6503 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6504 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6505 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations > Left I/P - Junction Block > Page 6506 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block Relay Box: Application and ID Left I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6509 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6510 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6511 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6512 Relay Box: Application and ID Right I/P - Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6513 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6514 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6515 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6516 Relay Box: Application and ID Underhood Bottom Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6517 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6518 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6519 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6520 Junction Block-Underhood Wire Entry Pinout - Bottom Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6521 Junction Block-Underhood Wire Entry Pinout - Bottom Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6522 Junction Block-Underhood Wire Entry Pinout - Bottom Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6523 Junction Block-Underhood Wire Entry Pinout - Bottom Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6524 Junction Block-Underhood Wire Entry Pinout - Bottom Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6525 Relay Box: Application and ID Underhood Top Junction Block Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6526 Application Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6527 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6528 Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6529 Junction Block - Underhood Wire Entry Pinout - Top Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6530 Junction Block - Underhood Wire Entry Pinout - Top Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6531 Junction Block - Underhood Wire Entry Pinout - Top Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6532 Junction Block - Underhood Wire Entry Pinout - Top Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Application and ID > Left I/P - Junction Block > Page 6533 Junction Block - Underhood Wire Entry Pinout - Top Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement Relay Box: Service and Repair Underhood Electrical Center or Junction Block Replacement UNDERHOOD ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Disconnect the positive battery cables from the underhood fuse block terminals. 3. Remove the tape from the wiring harness at the base of the underhood fuse block base. 4. Release the underhood fuse block(s) clip retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6536 5. Remove the fuse block(s) and wiring harness lifting up from the base and reposition from the base. 6. Remove the nuts from the underhood fuse block base. 7. Remove the underhood fuse block base from the shock tower. 8. Remove the underhood fuse block lower front terminal positive assurance retainers using a small flat-bladed tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6537 9. Remove the plastic shields from the battery cable and buss bar terminals, using a small flat-bladed tool to release the clip retainer. 10. Remove the bolts from the buss bar jumper bar. 11. Remove the buss bar jumper bar from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6538 12. Remove the fuses from the fuse block(s) to access the buss bar terminal release tabs. 13. Remove the buss bar(s) from the fuse block(s) using a terminal releasing tool, and pulling down and out on the buss bar. 14. Remove the buss bar(s) from the fuse block(s). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6539 15. Release the clip retainers from the underhood fuse block(s) battery cable and buss bar terminals using a small flat-bladed tool. 16. Remove the underhood fuse block(s) battery cable and buss bar terminals from the fuse block by pulling down. 17. Remove the fuse block and lamp wiring harness from the vehicle, if required. INSTALLATION PROCEDURE 1. Install the underhood fuse block(s) battery cable and buss bar terminals to the fuse block(s) by sliding up into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6540 2. Install the buss bar(s) to the fuse block(s) pressing into place until fully seated. 3. Position the underhood fuse block terminal positive assurance retainers to the fuse block(s). 4. Install the underhood fuse block(s) terminal positive assurance retainers pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6541 5. Install the fuses to the fuse block(s) that were removed to access the buss bar terminal release tabs. 6. Install the buss bar jumper bar to the fuse block(s). NOTE: Refer to Fastener Notice in Service Precautions. 7. Install the bolts to the buss bar jumper bar. Tighten Tighten the jumper bar bolts to 9 N.m (80 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6542 8. Install the plastic shields to the battery cable and buss bar terminals pressing into place until fully seated. 9. Position the underhood fuse block(s) to the underhood fuse block base retaining locks. 10. Install the underhood fuse block(s) into the underhood fuse block base retaining locks pressing in until fully seated. 11. Install new tape to the wiring harness at the base of the underhood fuse block base. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6543 12. Position the underhood fuse block base to the shock tower. 13. Install the nuts to the underhood fuse block base. Tighten Tighten the fuse block base nuts to 9 N.m (80 lb in). 14. Install the positive battery cables to the underhood fuse block. Tighten Tighten the positive battery cables nuts to 15 N.m (11 lb ft). 15. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6544 Relay Box: Service and Repair Instrument Panel Electrical Center / Junction Block Replacement Left INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left I/P fuse block access hole cover. 3. Disconnect the outboard wiring harness connector C2 from the junction block. 4. Remove the connector position assurance (CPA) from the yellow inflatable restraint connector. Disconnect and reposition the yellow inflatable restraint connector for access to the bolts. 5. Remove the steering column filler. 6. Remove the I/P driver knee bolster. 7. Disconnect the inner wiring harness connector from the junction block. 8. Remove the junction block bolts. 9. Remove the junction block tab from the slot in the cross vehicle beam. Pull the junction block away from the I/P. 10. Remove the junction block. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6545 1. Install the junction block tab to the slot in the cross vehicle beam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the junction block bolts. Tighten Tighten the junction block bolts to 10 N.m (89 lb in). 3. Connect the inner wiring harness connector to the junction block. Tighten Tighten the inner wiring harness connector bolt to 7 N.m (62 lb in). 4. Install the I/P driver knee bolster. 5. Install the steering column filler. 6. Connect the yellow inflatable restraint connector. Install the CPA. Attach the connector to the junction block. 7. Connect the outboard wiring harness connector C2 to the junction block. Tighten Tighten the body wiring harness connector bolt to 7 N.m (62 lb in). 8. Install the left I/P fuse block access hole cover. 9. Connect the negative battery cable. Right INSTRUMENT PANEL ELECTRICAL CENTER OR JUNCTION BLOCK REPLACEMENT - RIGHT Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6546 REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the RH instrument panel (IP) fuse block access opening cover. 3. Disconnect the body wiring harness from the junction block. 4. Open the IP compartment. Access the junction block bolt through the open IP compartment. Remove the junction block bolt. 5. Disengage the junction block tabs from the passenger knee bolster. Pull the junction block away from the IP. 6. Disconnect the wiring harnesses from the junction block. 7. Remove the junction block. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6547 1. Connect the body wiring harnesses to the junction block. Tighten Tighten the body wiring harness connector bolts to 7 N.m (62 lb in). 2. Install the junction block tabs to the passenger knee bolster. 3. Install the junction block bolt. Tighten Tighten the junction block bolt to 10 N.m (89 lb in). 4. Close the IP compartment. 5. Connect the body wiring harness to the junction block. 6. Install the RH IP fuse block access opening cover. 7. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6548 Relay Box: Service and Repair Junction Block Replacement - Accessory Wiring JUNCTION BLOCK REPLACEMENT - ACCESSORY WIRING REMOVAL PROCEDURE 1. Disconnect the negative battery cable. 2. Remove the left instrument panel (I/P) insulator. 3. Remove the screws from the accessory wiring junction block. 4. Adjust the junction block for access. 5. Remove the circuit breakers (4) and the relays from the junction block as required. 6. If necessary remove the junction block from the bracket assembly. INSTALLATION PROCEDURE 1. If necessary install the junction block to the bracket assembly. 2. Install the circuit breakers (4) and the relays to the junction block as required. 3. Position the junction block to the I/P carrier. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the junction block screws. Tighten Tighten the screws to 10 N.m (89 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Service and Repair > Underhood Electrical Center or Junction Block Replacement > Page 6549 5. Install the left I/P insulator. 6. Connect the negative battery cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6558 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6559 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > Customer Interest: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6560 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Wiring Harness: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6566 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6567 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 6568 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6573 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6574 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6575 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6576 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6577 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6578 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 6583 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair Wiring Harness: All Technical Service Bulletins Electrical - Information For Electrical Ground Repair INFORMATION Bulletin No.: 10-08-45-001B Date: October 25, 2010 Subject: Information for Electrical Ground Repair - Use New Replacement Fasteners with Conductive Finish Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2011 model year and update the Warranty Information. Please discard Corporate Bulletin Number 10-08-45-001A (Section 08 - Body and Accessories). Electrical Ground Repair Overview Proper electrical system function relies on secure, stable and corrosion-free electrical ground connections. Loose, stripped, or corroded connections increase the possibility of improper system function and loss of module communication. These conditions may also lead to unnecessary repairs and component replacement. In general, electrical ground connections are accomplished using one, or a combination of the following attachment methods: - Welded M6 stud and nut - Welded M6 nut and bolt - Welded M8 nut and bolt Determine which attachment method is used and perform the appropriate or alternative repair as described in this bulletin. M6 Weld Stud Replacement Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. Select a location adjacent the damaged or missing M6 ground stud having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 3. Drill a 10 mm (0.40 in) diameter hole through the panel. 4. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6589 Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 5. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 6. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 7. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 8. Ensure the rivet stud is securely fastened, WITHOUT ANY detectable movement. 9. Completely wrap the threads of the rivet stud with painters tape or equivalent. Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 10. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 11. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 12. Remove the painters tape or equivalent from the rivet stud threads. 13. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 14. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6590 15. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 16. Install the electrical ground wire terminal to the rivet stud. 17. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 18. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in). 19. Verify proper system operation. M6 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M6 weld nut at the electrical ground location is damaged or stripped, a M7 conductive self-threading bolt may be used to secure the ground wire terminal. 2. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the weld nut and allow to dry. 3. Remove any loose metal particles from the damaged or stripped weld nut with a stiff brush. 4. Select a M7 conductive self-threading bolt. Refer to the Parts Information section of this bulletin 5. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M7 conductive self-threading bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 6. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 7. Install the electrical ground wire terminal to the M7 conductive self-threading bolt. 8. Install the M7 conductive self-threading bolt and: Tighten Tighten to 9 Nm (80 lb in). 9. Verify proper system operation. M6 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the electrical ground location is accessible from both sides of the panel, a M6 conductive bolt and a M6 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the damaged M6 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 8.5 mm (0.33 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 8.5 mm (0.33 in) hole until bare metal is visible. 6. Select a M6 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M6 conductive bolt to the ground location. 10. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M6 conductive nut to the bolt and: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6591 Tighten Tighten to 8 Nm (71 lb in). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is accessible from both sides of the panel, a M8 conductive bolt and a M8 conductive nut may be used to secure the electrical ground wire terminal. Refer to the Parts Information section of this bulletin. 2. Select a location adjacent the M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the new electrical ground site. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the surface surrounding the ground location and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) hole until bare metal is visible. 6. Select a M8 conductive bolt. Refer to the Parts Information section of this bulletin. 7. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M8 conductive bolt. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 8. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 9. Install the electrical ground wire terminal and the M8 conductive bolt to the ground location. 10. Select a M8 conductive nut. Refer to the Parts Information section of this bulletin. 11. Install the M8 conductive nut to the bolt and: Tighten Tighten to 22 Nm (16 lb ft). Note The repair area MUST BE properly refinished to maintain a secure, stable and corrosion-free electrical ground. 12. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 13. Verify proper system operation. M8 Weld Nut Alternative Repair Caution Use only the GM-approved replacement fasteners with conductive finish for electrical ground repair. 1. If the M8 weld nut electrical ground location is not accessible from both sides of the panel, a M6 conductive rivet stud and a M6 conductive nut may be used to secure the electrical ground wire terminal. 2. Select a location adjacent the damaged M8 weld nut having 20 mm (0.79 in) clearance behind the panel surface and 20 mm (0.79 in) clearance surrounding the M6 conductive rivet stud flange. 3. Using GM approved residue-free solvent or equivalent, remove any grease from the repair site and allow to dry. Note Ensure 20 mm (0.79 in) clearance is maintained behind the panel to be drilled. 4. Drill a 10 mm (0.40 in) diameter hole through the panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6592 5. Remove paint and primer from the area surrounding the 10 mm (0.40 in) until bare metal is visible. Important The M6 conductive rivet stud as shown, can accommodate a panel thickness range of 0.7-4.2 mm (0.03-0.17 in). If there are layers of sheet metal, they should be touching without any air gaps to ensure a good ground. 6. Select a M6 conductive rivet stud. Refer to the Parts Information section of this bulletin. Note Use the GE-50317 rivet stud tool kit. 7. Place the M6 conductive rivet stud (1) in the 10 mm (0.40 in) hole. Assemble the rivet stud tool (2) with the groove and flare side facing the rivet stud, then the washer and the M6 nut (3). 8. Using a wrench on the rivet stud tool, and a socket on the M6 nut, secure the M6 conductive rivet stud. 9. Ensure the new rivet stud is securely fastened, WITHOUT ANY detectable movement. 10. Completely wrap the threads of the rivet stud with painters tape or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6593 Note The rivet stud and surrounding panel area MUST BE properly refinished PRIOR to the installation of the electrical ground wire terminal and conductive nut to maintain a secure, stable and corrosion-free electrical ground. 11. Refinish the repair area using an anti-corrosion primer. Refer to Anti-Corrosion Treatment and Repair in SI. 12. Allow the refinished repair area to cure sufficiently before removing the protective material applied to the rivet stud threads. 13. Remove the painters tape or equivalent from the rivet stud threads. 14. Using GM approved residue-free solvent or equivalent, thoroughly clean the rivet stud threads to remove any adhesive and allow to dry. 15. Using a small brush, apply Dielectric Lubricant GM P/N 12377900 (Canadian P/N 10953529) to the threads of the M6 conductive rivet stud. Note Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can accumulate at the electrical contact points causing the electrical resistance across the connection to increase. 16. Carefully remove ANY corrosion or contamination that may be present on the electrical ground wire terminal. 17. Install the electrical ground wire terminal to the M6 conductive rivet stud. 18. Select a M6 conductive nut. Refer to the Parts Information section of this bulletin. 19. Install the M6 conductive nut to the rivet stud and: Tighten Tighten to 8 Nm (71 lb in) 20. Verify proper system operation. Parts Information Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 10-08-45-001B > Oct > 10 > Electrical - Information For Electrical Ground Repair > Page 6594 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair Wiring Harness: All Technical Service Bulletins Electrical - Instrument Panel & General Wiring Repair Bulletin No.: 06-08-45-004 Date: May 02, 2006 INFORMATION Subject: Instrument Panel (I/P), Body and General Wiring Harness Repair Models: 2007 and Prior GM Cars and Trucks 2003-2007 HUMMER H2 2006-2007 HUMMER H3 Important: A part restriction has been implemented on all Body and I/P harnesses and is being administered by the PQC. If a body or I/P harness replacement is required, it can take 12-28 weeks for a harness to be built and delivered to a dealer. The dealer technician is expected to repair any harness damage as the first and best choice before replacing a harness. In an effort to standardize repair practices, General Motors is requiring that all wiring harnesses be repaired instead of replaced. If there is a question concerning which connector and/or terminal you are working on, refer to the information in the appropriate Connector End Views in SI. The Instruction Manual J 38125-620, which is sent with each new update of the J 38125 Terminal Repair Kit, also has terminal crimping and terminal remove information. Important: There are some parts in the J 38125 Terminal Repair Kit (i.e. SIR connector CPAs and heat shrink tube (used in high heat area pigtail replacement) and some TPAs that are not available from GMSPO. It is vitally important that each update to the J 38125 Terminal Repair Kit be done as soon as it arrives at the dealer. Utilize the Terminal Repair Kit (J 38125) to achieve an effective wiring repair. The Terminal Repair Kit has been an essential tool for all GM Dealers since 1987. Replacement terminals and tools for this kit are available through SPX/Kent Moore. Refer to Corporate Bulletin Number 06-08-45-001 for more information. The Instruction Manual J 38125-620, which is sent with each new update to the J 38125 Terminal Repair Kit, also has terminal crimping and terminal removal information. U.S. Dealers Only - Training courses (including Tech Assists, Emerging Issues, Web, IDL and Hands-on) are available through the GM Training website. Refer to Resources and then Training Materials for a complete list of available courses. Canadian Dealers Only - Refer to the Training section of GM infoNet for a complete list of available courses and a copy of the J 38125 Terminal Repair Kit Instruction Manual. Wiring repair information is also available in Service Information (SI). The Wiring Repair section contains information for the following types of wiring repairs: - Testing for intermittent conditions and poor conditions - Flat wire repairs - GMLAN wiring repairs - High temperature wiring repairs - Splicing copper wire using splice clips - Splicing copper wire using splice sleeves - Splicing twisted or shielded cable - Splicing inline harness diodes Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wiring Harness: > 06-08-45-004 > May > 06 > Electrical - Instrument Panel & General Wiring Repair > Page 6599 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications Alignment: Technical Service Bulletins Steering/Suspension - Wheel Alignment Specifications WARRANTY ADMINISTRATION Bulletin No.: 05-03-07-009C Date: December 09, 2010 Subject: Wheel Alignment Specifications, Requirements and Recommendations for GM Vehicles Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks Supercede: This bulletin is being extensively revised to provide technicians and warranty administrators with an all inclusive guide for wheel alignments. PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. Please discard Corporate Bulletin Number 05-03-07-009B (Section 03 - Suspension). Purpose The purpose of this bulletin is to provide retail, wholesale and fleet personnel with General Motors' warranty service requirements and recommendations for customer concerns related to wheel alignment. For your convenience, this bulletin updates and centralizes all of GM's Standard Wheel Alignment Service Procedures, Policy Guidelines and bulletins on wheel alignment warranty service. Important PLEASE FAMILIARIZE YOURSELF WITH THESE UPDATES BEFORE PERFORMING YOUR NEXT GM WHEEL ALIGNMENT SERVICE. The following five (5) key steps are a summary of this bulletin and are REQUIRED in completing a successful wheel alignment service. 1. Verify the vehicle is in an Original Equipment condition for curb weight, tires, wheels, suspension and steering configurations. Vehicles modified in any of these areas are not covered for wheel alignment warranty. 2. Review the customer concern relative to "Normal Operation" definitions. 3. Verify that vehicle is within the "Mileage Policy" range. 4. Document wheel alignment warranty claims appropriately for labor operations E2000 and E2020. The following information must be documented or attached to the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 5. Use the proper wheel alignment equipment (preferred with print-out capability), process and the appropriate calibration maintenance schedules. Important If it is determined that a wheel alignment is necessary under warranty, use the proper labor code for the repair. E2000 for Steering Wheel Angle and/or Front Toe set or E2020 for Wheel Alignment Check/Adjust includes Caster, Camber and Toe set (Wheel alignment labor time for other component repairs is to be charged to the component that causes a wheel alignment operation.). The following flowchart is to help summarize the information detailed in this bulletin and should be used whenever a wheel alignment is performed. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6605 Verify Original Equipment Condition of the Vehicle - Verify that Original Equipment Tires and Wheels or Official GM Accessory Tires and Wheels are on the vehicle. - Verify that aftermarket suspension "Lift" or "Lowering" Kits or other suspension alterations have NOT been done to the vehicle. - Check for accidental damage to the vehicle; for example, severe pothole or curb impacts, collision damage that may have affected the wheel alignment of the vehicle; e.g., engine cradles, suspension control arms, axles, wheels, wheel covers, tires may show evidence of damage/impact. - Check to be sure vehicle has seen "Normal Use" rather than abuse; e.g., very aggressive driving may show up by looking at the tires and condition of the vehicle. - Check for other additional equipment items that may significantly affect vehicle mass such as large tool boxes, campers, snow plow packages (without the snowplow RPO), etc., especially in trucks and cutaway/incomplete vehicles. Significant additional mass can affect trim height and wheel alignment of the vehicle and may necessitate a customer pay wheel alignment when placed semi-permanently in the vehicle (Upfitter instructions are to realign the vehicle after placement of these types of items. (This typically applies to trucks and incomplete vehicles that can be upfit with equipment such as the above.) Customer Concerns, "Normal Operation" Conditions and "Mileage Policy" Possible Concerns The following are typical conditions that may require wheel alignment warranty service: 1. Lead/Pull: defined as "at a constant highway speed on a typical straight road, the amount of effort required at the steering wheel to maintain the vehicle's straight heading." Important Please evaluate for the condition with hands-on the steering wheel. Follow the "Vehicle Leads/Pulls" diagnostic tree located in SI to determine the cause of a lead/pull concern. Lead/Pull concerns can be due to road crown or road slope, tires, wheel alignment or even in rare circumstances a steering gear issue. Lead/pull concerns due to road crown are considered "Normal Operation" and are NOT a warrantable condition -- the customer should be advised that this is "Normal Operation." Important Some customers may comment on a "Lead/Pull" when they hold the steering wheel in a level condition. If so, this is more likely a "steering wheel angle" concern because the customer is "steering" the vehicle to obtain a "level" steering wheel. 2. Steering wheel angle to the left or right (counter-clockwise or clockwise, respectively): Defined as the steering wheel angle (clocking) deviation from "level" while maintaining a straight heading on a typical straight road. 3. Irregular or Premature tire wear: Slight to very slight "feathering" or "edge" wear on the shoulders of tires is NOT considered unusual and should even out with a tire rotation; if the customer is concerned about a "feathering" condition of the tires, the customer could be advised to rotate the tires earlier than the next scheduled mileage/maintenance interval (but no later than the next interval). Be sure to understand the customer's driving habits as this will also heavily influence the tire wear performance; tire wear from aggressive or abusive driving habits is NOT a warrantable condition. Important Slight or mild feathering, cupping, edge or heel/toe wear of tire tread shoulders is "normal" and can show up very early in a tire/vehicle service mileage; in fact, some new tires can show evidence of feathering from the factory. These issues do NOT affect the overall performance and tread life of the tire. Dealer personnel should always check the customer's maintenance records to ensure that tire inflation pressure is being maintained to placard and that the tires are being rotated (modified-X pattern) at the proper mileage intervals. Wheel alignments are NOT to be performed for the types of "Normal" Tire Feathering shown in Figures 1-4 below. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6606 Figure 1: Full Tread View - "NORMAL" Tire "Feathering" Wear on the Shoulder/Adjacent/Center Ribs Figure 2: Tire Shoulder View Example 1 - "NORMAL" Tire "Feathering" Wear on the Shoulder Figure 3: Tire Shoulder View Example 2 - "NORMAL" Tire "Feathering" Wear Figure 4: Detail Side View of Tire Shoulder Area - "NORMAL" Tire "Feathering" Wear Important When a wheel alignment is deemed necessary for tire wear, be sure to document on the repair order, in as much detail as possible, the severity and type of tire wear (e.g., severe center wear or severe inside or outside shoulder wear) and the position of the tire on the vehicle (RF, LF, LR, RR). Please note the customer's concern with the wear such as, noise, appearance, wear life, etc. A field product report with pictures of the tire wear condition is recommended. Refer to Corporate Bulletin Number 02-00-89-002J and #07-00-89-036C. 4. Other repairs that affect wheel alignment; e.g., certain component replacement such as suspension control arm replacement, engine cradle adjustment/replace, steering gear replacement, steering tie rod replace, suspension strut/shock, steering knuckle, etc. may require a wheel alignment. Important If other components or repairs are identified as affecting the wheel alignment, policy calls for the wheel alignment labor time to be charged to the replaced/repaired component's labor operation time rather than the wheel alignment labor operations. Important Vibration type customer concerns are generally NOT due to wheel alignment except in the rare cases; e.g., extreme diagonal wear across the tread. In general, wheel alignments are NOT to be performed as an investigation/correction for vibration concerns. "Normal Operation" Conditions Vehicle Lead/Pull Due to Road Crown or Slope: As part of "Normal Operation," vehicles will follow side-to-side or left to right road crown or slope. Be sure to verify from the customer the types of roads they are driving as they may not recognize the influence of road crown on vehicle lead/pull and steering wheel angle. If a vehicle requires significant steering effort to prevent it from "climbing" the road crown there may be an issue to be looked into further. Important Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6607 A wheel alignment will generally NOT correct vehicles that follow the road crown since this is within "Normal Operation." Mileage Policy The following mileage policy applies for E2020 and E2000 labor operations: Note Wheel Alignment is NOT covered under the New Vehicle Limited Warranty for Express and Savana Cutaway vehicles as these vehicles require Upfitters to set the wheel alignment after completing the vehicles. - 0-800 km (0-500 mi): E2000/E2020 claims ONLY allowed with Call Center Authorization. Due to the tie down during shipping, the vehicle's suspension requires some time to reach normal operating position. For this reason, new vehicles are generally NOT to be aligned until they have accumulated at least 800 km (500 mi). A field product report should accompany any claim within this mileage range. - 801-12,000 km (501-7,500 mi): - If a vehicle came from the factory with incorrect alignment settings, any resulting off-angle steering wheel, lead/pull characteristics or the rare occurrence of excessive tire wear would be apparent early in the life of the vehicle. The following policy applies: - Vehicles 100% Factory Set/Measured for Caster/Camber/Toe - Escalade/ESV/EXT, Tahoe/Suburban, Yukon/XL/Denali, Silverado/Sierra, Express/Savana, Corvette and Colorado/Canyon: E2000/E2020 Claims: Call Center Authorization Required - All Vehicles NOT 100% Factory Set/Measured for Caster/Camber/Toe as noted above: E2000/E2020 Claims: Dealer Service Manager Authorization Required - 12,001 km and beyond (7,501 miles and beyond): During this period, customers are responsible for the wheel alignment expense or dealers may provide on a case-by case basis a one-time customer enthusiasm claim up to 16,000 km (10,000 mi). In the event that a defective component required the use of the subject labor operations, the identified defective component labor operation will include the appropriate labor time for a wheel alignment as an add condition to the component repair. Important Only one wheel alignment labor operation claim (E2000 or E2020) may be used per VIN. Warranty Documentation Requirements When a wheel alignment service has been deemed necessary, the following items will need to be clearly documented on/with the repair order: - Customer concern in detail - What corrected the customer concern? - If a wheel alignment is performed: - Consult SI for proper specifications. - Document the "Before" AND "After" wheel alignment measurements/settings. - Completed "Wheel Alignment Repair Order Questionnaire" (form attached to this bulletin) 1. Document the customer concern in as much detail as possible on the repair order and in the warranty administration system. Preferred examples: - Steering wheel is off angle in the counterclockwise direction by approximately x degrees or clocking position. - Vehicle lead/pulls to the right at approximately x-y mph. Vehicle will climb the road crown. Severe, Moderate or Slight. - RF and LF tires are wearing on the outside shoulders with severe feathering. Important In the event of a lead/pull or steering wheel angle concern, please note the direction of lead/pull (left or right) or direction of steering wheel angle (clockwise or counterclockwise) on the repair order and within the warranty claim verbatim. Important In the event of a tire wear concern, please note the position on the vehicle and where the wear is occurring on the tire; i.e., the RF tire is wearing on the inside shoulder. 2. Document the technician's findings on cause and correction of the issue. Examples: - Reset LF toe from 0.45 degrees to 0.10 degrees and RF toe from -0.25 degrees to 0.10 degrees to correct the steering wheel angle from 5 degrees counterclockwise to 0 degrees. - Reset LF camber from 0.25 degrees to -0.05 degrees to correct the cross-camber condition of +0.30 degrees to 0.00 degrees on the vehicle. - Front Sum toe was found to be 0.50 degrees, reset to 0.20 degrees. 3. Print-out the "Before" and "After" wheel alignment measurements/settings and attach them to the Repair Order or if print-out capability is not Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6608 available, measurements may also be clearly and legibly handwritten into the Wheel Alignment Repair Order Questionnaire attached to this bulletin. 4. Attach the Wheel Alignment Repair Order Questionnaire below along with the print-out of "Before" and "After" wheel alignment measurements to the Repair Order and retain for use by GM. Wheel Alignment Equipment and Process Wheel alignments must be performed with a quality machine that will give accurate results when performing checks. "External Reference" (image-based camera technology) is preferred. Please refer to Corporate Bulletin Number 05-00-89-029B: General Motors Dealership Critical Equipment Requirements and Recommendations. Requirements: - Computerized four wheel alignment system. - Computer capable of printing before and after alignment reports. - Computer capable of time and date stamp printout. - Racking system must have jacking capability - Racking system must be capable of level to 1.6 mm (1/16 in) - Appropriate wheel stops and safety certification - Built-in turn plates and slip plates - Wheel clamps capable of attaching to 20" or larger wheels - Racking capable of accepting any GM passenger car or light duty truck - Operator properly trained and ASE-certified (U.S. only) in wheel alignment Recommendations: Racking should have front and rear jacking capability. Equipment Maintenance and Calibration: Alignment machines must be regularly calibrated in order to give correct information. Most manufacturers recommend the following: - Alignment machines with "internal reference" sensors should be checked (and calibrated, if necessary) every six months. - Alignment machines with "external reference" (image-based camera technology) should be checked (and calibrated, if necessary) once a year. - Racks must be kept level to within 1.6 mm (1/16 in). - If any instrument that is part of the alignment machine is dropped or damaged in some way, check the calibration immediately. Check with the manufacturer of your specific equipment for their recommended service/calibration schedule. Wheel Alignment Process When performing wheel alignment measurement and/or adjustment, the following steps should be taken: Preliminary Steps: 1. Verify that the vehicle has a full tank of fuel (compensate as necessary). 2. Inspect the wheels and the tires for damage. 3. Inspect the tires for the proper inflation and irregular tire wear. 4. Inspect the wheel bearings for excessive play. 5. Inspect all suspension and steering parts for looseness, wear, or damage. 6. Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. 7. Inspect the vehicle trim height. 8. Compensate for frame angle on targeted vehicles (refer to Wheel Alignment Specifications in SI). Satisfactory vehicle operation may occur over a wide range of alignment angles. However, if the wheel alignment angles are not within the range of specifications, adjust the wheel alignment to the specifications. Refer to Wheel Alignment Specifications in SI. Give consideration to excess loads, such as tool boxes, sample cases, etc. Follow the wheel alignment equipment manufacturer's instructions. Measure/Adjust: Important Prior to making any adjustments to wheel alignment on a vehicle, technicians must verify that the wheel alignment specifications loaded into their wheel alignment machine are up-to-date by comparing these to the wheel alignment specifications for the appropriate model and model year in SI. Using incorrect and/or outdated specifications may result in unnecessary adjustments, irregular and/or premature tire wear and repeat customer concerns Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6609 Important When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front wheel alignment angles. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. If necessary, adjust the wheel alignment to vehicle specification and record the before and after measurements. Refer to Wheel Alignment Specifications in SI. Important Technicians must refer to SI for the correct wheel alignment specifications. SI is the only source of GM wheel alignment specifications that is kept up-to-date throughout the year. Test drive vehicle to ensure proper repair. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6610 Frame Angle Measurement (Express / Savana Only) ........ Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Technical Service Bulletins > Steering/Suspension - Wheel Alignment Specifications > Page 6611 What corrected the customer concern and was the repair verified? Please Explain: ............. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications Trim Height Specifications Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications > Page 6614 Alignment: Specifications Wheel Alignment Specifications WHEEL ALIGNMENT SPECIFICATIONS FRONT SUSPENSION CAMBER Service Allowable ................................................................................................................................ ................................................ -0.28 to -1.28° Service Preferred ........................................................ ...................................................................................................................................... -0.78° CASTER Service Allowable ................................................................................................................................ ................................................. 2.70 to 3.70° Service Preferred ......................................................... ....................................................................................................................... Not Adjustable STEERING ANGLE Service Allowable ................................................................................................................................ ............................................... -3.50 to +3.50° Service Preferred ........................................................ ............................................................................................................................................ 0° TOE - TOTAL Service Allowable ................................................................................................................................ ............................................... -0.10 to +0.30° Service Preferred ........................................................ ....................................................................................................................................... 0.10° REAR SUSPENSION CAMBER Service Allowable ................................................................................................................................ ................................................... -1.0 to +0.0° Service Preferred ........................................................ ....................................................................................................................................... -0.50° THRUST ANGLE Service Allowable ................................................................................................................................ ............................................... -0.15 to +0.15° Service Preferred ........................................................ ............................................................................................................................................ 0° TOE - TOTAL Service Allowable ................................................................................................................................ ............................................... -0.10 to +0.30° Service Preferred ........................................................ ....................................................................................................................................... 0.10° Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Trim Height Specifications > Page 6615 Fastener Tightening Specifications Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6616 Alignment: Description and Operation Description and Operation Caster Description Caster is the tilting of the uppermost point of the steering axis either forward or backward, when viewed from the side of the vehicle. A backward tilt is positive (+) and a forward tilt is negative (-). Caster influences directional control of the steering but does not affect the tire wear. Caster is affected by the vehicle height, therefore it is important to keep the body at its designed height. Overloading the vehicle or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower than its designated trim height, the front suspension moves to a more positive caster. If the rear of the vehicle is higher than its designated trim height, the front suspension moves to a less positive caster. With too little positive caster, steering may be touchy at high speed and wheel returnability may be diminished when coming out of a turn. If one wheel has more positive caster than the other, that wheel will pull toward the center of the vehicle. This condition will cause the vehicle to pull or lead to the side with the least amount of positive caster. Camber Description Camber is the tilting of the wheels from the vertical when viewed from the front of the vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the wheel tilts inward at the top, the camber is negative (-). The amount of tilt is measured in degrees from the vertical. Camber settings influence the directional control and the tire wear. Too much positive camber will result in premature wear on the outside of the tire and cause excessive wear on the suspension parts. Too much negative camber will result in premature wear on the inside of the tire and cause excessive wear on the suspension parts. Unequal side-to-side camber of 1 degree or more will cause the vehicle to pull or lead to the side with the most positive camber. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6617 Toe Description Toe is a measurement of how much the front and/or rear wheels are turned in or out from a straight-ahead position. When the wheels are turned in, toe is positive (+). When the wheels are turned out, toe is negative (-). The actual amount of toe is normally only a fraction of a degree. The purpose of toe is to ensure that the wheels roll parallel. Toe also offsets the small deflections of the wheel support system that occur when the vehicle is rolling forward. In other words, with the vehicle standing still and the wheels set with toe-in, the wheels tend to roll parallel on the road when the vehicle is moving. Improper toe adjustment will cause premature tire wear and cause steering instability. Setback Description Setback applies to both the front and the rear wheels. Setback is the amount that one wheel may be aligned behind the other wheel. Setback may be the result of a road hazard or a collision. The first clue is a caster difference from side-to-side of more than 1 degree. Thrust Angles Description The front wheels aim or steer the vehicle. The rear wheels control tracking. This tracking action relates to the thrust angle (3). The thrust angle is the path that the rear wheels take. Ideally, the thrust angle is geometrically aligned with the body centerline (2). In the illustration, toe-in is shown on the left rear wheel, moving the thrust line (1) off center. The resulting deviation from the centerline is the thrust angle. Lead/Pull Description Lead/pull is the deviation of the vehicle from a straight path, on a level road, without hand pressure on the steering wheel. Lead/pull is usually caused by the following factors: ^ Tire construction ^ Uneven brake adjustment ^ Wheel alignment The way in which a tire is built may produce lead/pull. The rear tires will not cause lead. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6618 Torque Steer Description A vehicle pulls or leads in one direction during hard acceleration. A vehicle pulls or leads in the other direction during deceleration. The following factors may cause torque steer to be more apparent on a particular vehicle: ^ A slightly smaller diameter tire on the right front increases a right torque lead. Inspect the front tires for differences in the brand, the construction, ^ or the size. If the tires appear to be similar, change the front tires from side-to-side and retest the vehicle. Tire and wheel assemblies have the most significant effect on torque steer correction. ^ A large difference in the right and left front tire pressure ^ Left-to-right differences in the front view axle angle may cause significant steering pull in a vehicle. The pull will be to the side with the most downward sloping axle from the differential to the wheels. Axles typically slope downward from the differential. The slope of the transaxle pan to level ground may be used as an indication of bias axle angles. The side with the higher transaxle pan, shown on the left side of the illustration, has the most downward sloping axle angle. Memory Steer Description Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle. Additionally, after turning in the opposite direction, the vehicle will want to lead or pull in that direction. Wander Description Wander is the undesired drifting or deviation of a vehicle to either side from a straight path with hand pressure on the steering wheel. Wander is a symptom of the vehicle's sensitivity to external disturbances, such as road crown and crosswind, and accentuated by poor on-center steering feel. Scrub Radius Description Ideally, the scrub radius is as small as possible. Normally, the SAI angle and the centerline of the tire and the wheel intersect below the road surface, causing a positive scrub radius. With struts, the SAI angle is much larger than the long arm/short arm type of suspension. This allows the SAI angle to intersect the camber angle above the road surface, forming a negative scrub radius. The smaller the scrub radius, the better the directional stability. Installing aftermarket wheels that have additional offset will dramatically increase the scrub radius. The newly installed wheels may cause the centerline of the tires to move further away from the spindle. This will increase the scrub radius. A large amount of scrub radius can cause severe shimmy after hitting a bump. Four-wheel drive vehicles with large tires use a steering damper to compensate for an increased scrub radius. Scrub radius is not directly measurable by the conventional methods. Scrub radius is projected geometrically by engineers during the design phase of the suspension. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure Alignment: Service and Repair Trim Height Inspection Procedure Trim Height Inspection Procedure Trim Height Measurements Trim height is a predetermined measurement relating to vehicle ride height. Incorrect trim heights can cause bottoming out over bumps, damage to the suspension components and symptoms similar to wheel alignment problems. Check the trim heights when diagnosing suspension concerns and before checking the wheel alignment. Perform the following before measuring the trim heights: 1. Set the tire pressures to the pressure shown on the certification label. 2. Check the fuel level. Add additional weight if necessary to simulate a full tank. 3. Make sure the rear compartment is empty except for the spare tire. 4. Make sure the vehicle is on a level surface, such as an alignment rack. 5. Close the doors. 6. Close the hood. 7. All dimensions are measured vertical to the ground. Trim heights should be within 13 mm (0.5 in.) to be considered correct. Z Height Measurement The Z height dimension measurement determines the proper ride height for the front end of the vehicle. There is no adjustment procedure. Repair may require replacement of suspension components. 1. Lift the front bumper of the vehicle up about 38 mm (1.5 in.). 2. Gently remove your hands. Let the vehicle settle. 3. Repeat this operation for a total of 3 times. 4. Measure from the pivot bolt center line down to the lower corner of the lower ball joint in order to obtain the Z height measurement. 5. Push the front bumper of the vehicle down about 38 mm (1.5 in.). 6. Gently remove your hands. 7. Allow the vehicle to settle into position. 8. Repeat the jouncing operation 2 more times for a total of 3 times. 9. Measure the Z dimension. 10. The true Z height dimension number is the average of the high and the low measurements. D Height Measurement The D height dimension measurement determines the proper rear end ride height. There is no adjustment procedure. Repair may require replacement of suspension components. 1. With the vehicle on a flat surface, lift upward on the rear bumper 38 mm (1.5 in.). 2. Gently remove your hands. Allow the vehicle to settle into position. 3. Repeat the jouncing operation 2 more times for a total of 3 times. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 6621 4. The D height is measured from a point 30 mm (1.1 in.) outboard of the rear brake hose bracket bolt centerline to the bolt centerline of the trailing arm to the knuckle attachment. 5. Push the rear bumper downward to 38 mm (1.5 in.). 6. Gently remove your hands. Allow the vehicle to settle into position. 7. Repeat the jouncing operation 2 more times for a total of 3 times. 8. Measure the D height dimension. 9. The true D height dimension number is the average of the high and the low measurements. 10. If these measurements are out of specifications, inspect for the following conditions: ^ Improper weight distribution ^ Collision damage ^ Worn or damaged suspension components Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 6622 Alignment: Service and Repair Measuring Wheel Alignment Measuring Wheel Alignment Steering and vibration complaints are not always the result of improper alignment. One possible cause is wheel and tire imbalance. Another possibility is tire lead due to worn or improperly manufactured tires. Lead is the vehicle deviation from a straight path on a level road without pressure on the steering wheel. Refer to Radial Tire Lead/Pull Correction in order to determine if the vehicle has a tire lead problem. Before performing any adjustment affecting wheel alignment, perform the following inspections and adjustments in order to ensure correct alignment readings: ^ Inspect the tires for the proper inflation and irregular tire wear. ^ Inspect the runout of the wheels and the tires. ^ Inspect the wheel bearings for backlash and excessive play. ^ Inspect the ball joints and tie rod ends for looseness or wear. ^ Inspect the control arms and stabilizer shaft for looseness or wear. Notice: Refer to Fastener Notice in Service Precautions. ^ Inspect the steering gear for looseness at the frame. ^ Inspect the struts/shock absorbers for wear, leaks and any noticeable noises. ^ Inspect the vehicle trim height. ^ Inspect the steering wheel for excessive drag or poor return due to stiff or rusted linkage or suspension components. ^ Inspect the fuel level. The fuel tank should be full or the vehicle should have a compensating load added. Give consideration to excess loads, such as tool boxes, sample cases, etc. If normally carried in the vehicle, these items should remain in the vehicle during alignment adjustments. Give consideration also to the condition of the equipment being used for the alignment. Follow the equipment manufacturer's instructions. Satisfactory vehicle operation may occur over a wide range of alignment settings. However, if the setting exceeds the service allowable specifications, correct the alignment to the service preferred specifications. Perform the following steps in order to measure the front and rear alignment angles: 1. Install the alignment equipment according to the manufacturer's instructions. 2. Jounce the front and the rear bumpers 3 times prior to checking the wheel alignment. 3. Measure the alignment angles and record the readings. Important: When performing adjustments to vehicles requiring a 4-wheel alignment, set the rear wheel alignment angles first in order to obtain proper front alignment angles. 4. Adjust alignment angles to vehicle specification, if necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 6623 Alignment: Service and Repair Rear Wheel Alignment Rear Camber Adjustment Removal Procedure 1. Raise the vehicle and provide suitable support. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies. 3. Remove the strut from the vehicle. 4. Place the strut in a vise and file the upper strut-to-knuckle hole lateral - oblong. Compare the appearance of the holes before filing (2) with l after filing (3). Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the strut to the vehicle. ^ Tighten the strut-to-knuckle bolts as far as to allow movement of the knuckle. 2. Install the tire and wheel assemblies. 3. Adjust the camber (1). ^ Tighten the strut-to-knuckle bolts to 122 Nm (90 ft. lbs.). 4. Lower the vehicle. Rear Toe Adjustment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 6624 1. Loosen the hex nuts at the rear wheel spindle rod - rear. 2. Turn the adjusting nut to change the toe angle. 3. Adjust the toe to the proper setting. Notice: Refer to Fastener Notice in Service Precautions. 4. Tighten the hex nuts on the rear wheel spindle rod - rear. ^ Tighten the rear wheel spindle rod ends hex nuts to 50 Nm (37 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 6625 Alignment: Service and Repair Front Wheel Alignment Front Camber Adjustment Removal Procedure 1. Raise the vehicle and provide suitable support. Refer to Vehicle Lifting. 2. Remove the tire and wheel assemblies from the front and the rear axles. 3. Remove the strut from the vehicle. 4. Place the strut in a vise and file the hole lateral -oblong. Compare the appearance of the holes before filing (2) with after filing (3). 5. File the lower strut-to-knuckle attaching hole for a front camber adjustment. Installation Procedure Notice: Refer to Fastener Notice in Service Precautions. 1. Install the strut to the vehicle. ^ Tighten the strut-to-knuckle nuts as far as to allow movement of the knuckle. 2. Install the tire and wheel assemblies. 3. Adjust the camber (1). ^ Tighten the strut-to-knuckle nuts to 120 Nm (89 ft. lbs.). 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Trim Height Inspection Procedure > Page 6626 Front Toe Adjustment 1. Remove the small seal clamp from the inner tie rod boot. 2. Position the steering wheel in the straight ahead position. 3. Loosen the hex nut on the tie rod (2). Turn the tie rod shaft (1) in order to obtain the proper toe angle. 4. Confirm the number of threads showing on each tie rod end is nearly equal. Notice: Refer to Fastener Notice in Service Precautions. 5. Confirm that the tie rod ends (3) are square before you tighten the lock nuts (2). ^ Tighten the hex nuts at the tie rod ends to 68 Nm (50 ft. lbs.). Important: Ensure the seals do not twist. 6. Install the seal clamps. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Page 6627 Special Tools and Equipment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 6644 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Recalls for Front Steering Knuckle: > NHTSA04V287000 > Jun > 04 > Recall 04V287000: Caliper Mounting Bolt Torque Front Steering Knuckle: Recalls Recall 04V287000: Caliper Mounting Bolt Torque DEFECT: Certain passenger vehicles were produced with lower than specified torque on both front brake calipers to steering knuckle attachment bolts. With improper torque, the clamp load at the joint may not be adequate to prevent movement between the caliper bracket and knuckle. Depending on whether one or both bolts backs out or fractures, the result can be locking of the affected wheel during braking and an abrupt steering input in the direction of the locked wheel, reduced braking and noise from the affected wheel, or severing of a brake hose, increased brake pedal travel, and reduced steering control. Reduced braking or steering control could cause a crash. REMEDY: Dealers are to tighten both bolts to the specified torque. The manufacturer has reported that owner notification began on July 6, 2004. Owners may contact Chevrolet at 1-800-630-2438 or Pontiac at 1-800-620-7668. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > NHTSA04V287000 > Jun > 04 > Recall 04V287000: Caliper Mounting Bolt Torque Front Steering Knuckle: All Technical Service Bulletins Recall 04V287000: Caliper Mounting Bolt Torque DEFECT: Certain passenger vehicles were produced with lower than specified torque on both front brake calipers to steering knuckle attachment bolts. With improper torque, the clamp load at the joint may not be adequate to prevent movement between the caliper bracket and knuckle. Depending on whether one or both bolts backs out or fractures, the result can be locking of the affected wheel during braking and an abrupt steering input in the direction of the locked wheel, reduced braking and noise from the affected wheel, or severing of a brake hose, increased brake pedal travel, and reduced steering control. Reduced braking or steering control could cause a crash. REMEDY: Dealers are to tighten both bolts to the specified torque. The manufacturer has reported that owner notification began on July 6, 2004. Owners may contact Chevrolet at 1-800-630-2438 or Pontiac at 1-800-620-7668. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 6659 Front Steering Knuckle: Service and Repair Steering Knuckle Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the bearing/hub assembly. 3. Remove the front lower control arm ball stud. 4. Remove the outer tie rod end from the steering knuckle. 5. Scribe the strut to the knuckle. 6. Remove the bolts and nuts attaching the strut to the knuckle. 7. Remove the knuckle from the vehicle. Installation Procedure 1. Install the knuckle to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 6660 2. Install the bolts and nuts attaching the strut to the knuckle. ^ Tighten the strut to knuckle bolts to 120 Nm (89 ft. lbs.). 3. Install the outer tie rod to the steering knuckle. 4. Connect the front lower control arm ball stud to the knuckle. 5. Install the front wheel drive shaft bearing. 6. Lower the vehicle. 7. Inspect the front wheel alignment and adjust if necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair Power Steering Bleeding: Service and Repair Bleeding the Power Steering System ^ Tools Required J 35555 Metal Mityvac - J 43485 Power Steering Bleeder Adapter Important: Hoses touching the frame, body, or engine may cause system noise. 1. Verify that the hoses do not touch any other part of the vehicle. Important: Loose connections may not leak, but could allow air into the steering system. 2. Verify that all hose connections are tight. Notice: If the power steering system has been serviced, an accurate fluid level reading cannot be obtained unless air is bled from the steering system. The air in the fluid may cause pump cavitation noise and may cause pump damage over a period of time. Important: Maintain the fluid level throughout the bleed procedure. 3. Remove the pump reservoir cap. Important: Use clean, new power steering fluid only. 4. Fill the pump reservoir with fluid to the FULL COLD level. 5. Attach the J 43485 to the J 35555 or equivalent. 6. Place the J 43485 on or in the pump reservoir filler neck. 7. Apply a vacuum of 68 kPa (20 in Hg) maximum. 8. Wait 5 minutes. Typical vacuum drop is 7 - 10 kPa (2 - 3 in Hg). If the vacuum does not remain steady, refer to Excessive Vacuum Drop Diagnosis. 9. Remove the J 43485 and the J 35555. 10. Reinstall the pump reservoir cap. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6665 11. Start the engine. Allow the engine to idle. 12. Turn off the engine. 13. Verify the fluid level. Repeat steps 11-13 until the fluid stabilizes. Important: Do not turn steering wheel to lock. 14. Start the engine. Allow the engine to idle. 15. Turn the steering wheel 180 - 360° in both directions 5 times. 16. Switch the ignition off. Notice: When adding fluid or making a complete fluid change, always use the proper power steering fluid. Failure to use the proper fluid will cause hose and seal damage and fluid leaks. 17. Verify the fluid level. 18. Remove the pump reservoir cap. 19. Attach the J 43485 to the J 35555 or equivalent. 20. Place the J 43485 on or in the pump reservoir filler neck. 21. Apply a vacuum of 68 kPa (20 in Hg) maximum. 22. Wait 5 minutes. 23. Remove the J 43485 and the J 35555. 24. Verify the fluid level. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6666 25. Reinstall the pump reservoir cap. Excessive Vacuum Drop Diagnosis 1. If the vacuum continues to drop, remove the pressure and return hose from the pump. 2. Install the plugs (1,2) supplied with the J 43485 into the pressure and return port. 3. Attach the J 43485 to the J 35555 or equivalent. 4. Place the J 43485 on or in the pump reservoir filler neck. 5. Apply a vacuum of 68 kPa (20 in Hg) maximum. 6. If the vacuum drops again, repair or replace the pump. If the vacuum holds steady, continue to check the other parts of the steering system. Important: Fluid must be free from bubbles and foam. Be aware of periodic bubbles that indicate a loose connection or leaking O-ring seal in the return hose or the pressure hose. Fluid must be free from discoloration. 7. Observe the fluid. 8. If condition persists, replace the following parts: ^ The return hose clamps ^ The return hose O-rings Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Bleeding > System Information > Service and Repair > Page 6667 ^ The pressure hose O-rings ^ The gear cylinder line O-rings ^ The reservoir to pump O-ring 9. Repeat the bleed procedure from the beginning. 10. Drive the vehicle approximately 16 km (10 mi) in order to warm the system to operating temperature. Evaluate vehicle on a smooth flat surface. 11. Verify the following conditions: ^ There is smooth power assist. ^ The vehicle operates quietly. ^ The pump maintains the proper fluid level. ^ There is not any leaking in the steering system. ^ The fluid is free of foam or discoloration. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 05-02-32-007D > Mar > 07 > Steering Steering Gear Leaks/Moan or Groan Noise Power Steering Fluid: Customer Interest Steering - Steering Gear Leaks/Moan or Groan Noise Bulletin No.: 05-02-32-007D Date: March 29, 2007 ENGINEERING INFORMATION Subject: EI05119 - Power Steering Gear Leak, Moan, Groan or Whine Noise (Diagnose and Repair as Necessary) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2004-2007 Chevrolet Impala, Monte Carlo 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to provide additional leak and noise diagnosis information. Please discard Corporate Bulletin Number 05-02-32-007C (Section 02 - Steering). Condition Some customers may comment on a power steering gear leak or that the gear appears to be leaking. Additionally, the customer may come into the dealership indicating they were told by an aftermarket service facility that the steering gear was leaking because the power steering reservoir was low on fluid and the gear showed an oil residue. Some customers may also comment on a power steering noise during steering maneuvers or while driving. Correction Inspect and diagnose the power steering system before any repairs are attempted using the procedure listed below. Because the power steering reservoir on 3800 V6-equipped vehicles is located behind and below the rear cylinder head, the fluid level may not be getting checked and/or topped off similar to other vehicles which have a reservoir that is located on the upper portion of the engine. This condition could be more prevalent with vehicles serviced at non-GM dealerships. Determine if the power steering system is full of oil. Adjust the fluid in the reservoir to the proper level. The lower fluid level could be the result of a variation in the original system fill. Plus, over time and mileage, the system purges any remaining air. Additionally, as the hoses expand and contract, the fluid level may drop as measured within the reservoir. Don't assume there is an external fluid leak just because the fluid level in the reservoir is down to the Add mark. Restart the engine and see if the noise goes away after turning the steering wheel lock to lock a few times. This will correct most, if not all, the vehicles with a noise condition. If the customer was told their was a power steering fluid leak by an aftermarket service facility because the power steering reservoir needed fluid and they saw oil residue on the power steering gear, then carefully inspect the gear and surrounding area for oil residue. Below are some causes as to why oil residue may be present. Oil residue on the body of the steering gear usually on the pinion area (left side) of the gear or on the convoluted boots. This condition could be caused by a small amount of oil that can drip out when the shipping plugs are removed from the gear, just prior to the installation of the P/S pressure and return lines being connected at the assembly plants. Gears should not be replaced for this condition. Oil residue on or near the pinion adjuster nut plug. During the gear assembly process the supplier uses grease to lubricate the pinion adjuster plug threads. In cases where a lot of grease was used on the adjuster plug threads, some grease can ooze out around the threads and when mixed with moisture and road grime, it can appear as though the plug is leaking. In some cases the heat generated from the exhaust system will start to liquefy some of the grease and cause it to run. Gears should not be replaced for this condition. Oil residue inside the convoluted boots. When the steering gear is assembled into the housing, grease is applied to the gear teeth. In some cases, if there is a lot of grease used, it will squeeze out of the gear teeth, soften and run down and collect in the bottom of the convolutes. This may have the appearance of a thick oil, especially in hot climates. Some technicians have seen this liquefied grease and thought is was power steering fluid. Gears should not be replaced for this condition. If the customer indicates that they have seen what they think was a leak, resembling oil residue, on their garage floor or driveway, or the technician sees Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > Customer Interest: > 05-02-32-007D > Mar > 07 > Steering Steering Gear Leaks/Moan or Groan Noise > Page 6676 drops of oil leaking, carefully inspect the power steering hydraulic system. The inspection should be performed while the engine is running and the steering wheel is rotated from lock to lock. If a leak is observed, then repair the source of the leak. If the noise is not the result of low power steering fluid, provide a complete description of when the noise happens and what type of noise it is; i.e. squeal, pop, clunk, tick, continuous rubbing, etc. If it is a pop or clunk noise, make sure you inspect the convoluted boots to determine if the inner tie rod is rubbing the boots. Replace the boot or boots only for this condition. If the noise is a clunk or pop noise and it's not the inner tie rod rubbing the convoluted boots, make sure to inspect the intermediate shaft for the slip stick condition. This should be done prior to replacing any steering gears. If amber/yellow tinted glasses and the "pen light" style of black light are used, the lithium in the grease will show up in greenish/yellow similar to the greenish/yellow dye used by many dealerships to test for leaks. Always use the black light recommended by GM Tools and clear glasses to inspect for dye in fluid leaks. If the source of the leak cannot be found by visual inspection, add dye, P/N 88861206 (in Canada, use P/N 88861259), and inspect the system using Black Light (J 28428-E or J 42220). The number of vehicles that will require a complete inspection using dye will be minimal based on the inspection of numerous steering gears returned for testing where the complaint was fluid leak and no leaks could be reproduced. If a steering gear is replaced because a leak was discovered using the dye test method, make sure the repair order has a description of where the leak was discovered. If the steering gear is replaced for a noise concern, make sure a complete description of the diagnosis appears on the repair order as described in Step 5 above. Steering gears replaced under warranty will continue to be on parts return and regional feedbacks will be processed on any gears which the customer complaint cannot be verified. Over 90% of all steering gears inspected have little or no explanation of the condition, the technician's diagnosis or reason for replacing the gears and/or did not have any indication that dye was used to find a leak. Parts Information Warranty Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 06-02-32-009B > Nov > 08 > Steering - Noise Diagnostics TSB References Power Steering Fluid: All Technical Service Bulletins Steering - Noise Diagnostics TSB References INFORMATION Bulletin No.: 06-02-32-009B Date: November 19, 2008 Subject: Overview of Steering System Noises Models: 2001-2004 Buick Regal 2001-2005 Buick Century 2005-2007 Buick Allure (Canada Only), LaCrosse 2000-2006 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 1998-2002 Oldsmobile Intrigue 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to remove reference to Corporate Bulletin Number 01-02-32-001 from the table below. Please discard Corporate Bulletin Number 06-02-32-009A (Section 02 - Steering). The purpose of this bulletin is to provide a quick reference for dealers to aid in locating the correct service bulletin for several different steering system noise concerns. Many customer concerns with the steering system involve specific symptoms (noises heard). Once the customer concern has been verified, the table above may help identify the correct bulletin to reference. If other symptoms are present, or if diagnosis indicates another cause not found in any of the three service bulletins, refer to SI to diagnose the repair customer concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise Power Steering Fluid: All Technical Service Bulletins Steering - Steering Gear Leaks/Moan or Groan Noise Bulletin No.: 05-02-32-007D Date: March 29, 2007 ENGINEERING INFORMATION Subject: EI05119 - Power Steering Gear Leak, Moan, Groan or Whine Noise (Diagnose and Repair as Necessary) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2004-2007 Chevrolet Impala, Monte Carlo 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to provide additional leak and noise diagnosis information. Please discard Corporate Bulletin Number 05-02-32-007C (Section 02 - Steering). Condition Some customers may comment on a power steering gear leak or that the gear appears to be leaking. Additionally, the customer may come into the dealership indicating they were told by an aftermarket service facility that the steering gear was leaking because the power steering reservoir was low on fluid and the gear showed an oil residue. Some customers may also comment on a power steering noise during steering maneuvers or while driving. Correction Inspect and diagnose the power steering system before any repairs are attempted using the procedure listed below. Because the power steering reservoir on 3800 V6-equipped vehicles is located behind and below the rear cylinder head, the fluid level may not be getting checked and/or topped off similar to other vehicles which have a reservoir that is located on the upper portion of the engine. This condition could be more prevalent with vehicles serviced at non-GM dealerships. Determine if the power steering system is full of oil. Adjust the fluid in the reservoir to the proper level. The lower fluid level could be the result of a variation in the original system fill. Plus, over time and mileage, the system purges any remaining air. Additionally, as the hoses expand and contract, the fluid level may drop as measured within the reservoir. Don't assume there is an external fluid leak just because the fluid level in the reservoir is down to the Add mark. Restart the engine and see if the noise goes away after turning the steering wheel lock to lock a few times. This will correct most, if not all, the vehicles with a noise condition. If the customer was told their was a power steering fluid leak by an aftermarket service facility because the power steering reservoir needed fluid and they saw oil residue on the power steering gear, then carefully inspect the gear and surrounding area for oil residue. Below are some causes as to why oil residue may be present. Oil residue on the body of the steering gear usually on the pinion area (left side) of the gear or on the convoluted boots. This condition could be caused by a small amount of oil that can drip out when the shipping plugs are removed from the gear, just prior to the installation of the P/S pressure and return lines being connected at the assembly plants. Gears should not be replaced for this condition. Oil residue on or near the pinion adjuster nut plug. During the gear assembly process the supplier uses grease to lubricate the pinion adjuster plug threads. In cases where a lot of grease was used on the adjuster plug threads, some grease can ooze out around the threads and when mixed with moisture and road grime, it can appear as though the plug is leaking. In some cases the heat generated from the exhaust system will start to liquefy some of the grease and cause it to run. Gears should not be replaced for this condition. Oil residue inside the convoluted boots. When the steering gear is assembled into the housing, grease is applied to the gear teeth. In some cases, if there is a lot of grease used, it will squeeze out of the gear teeth, soften and run down and collect in the bottom of the convolutes. This may have the appearance of a thick oil, especially in hot climates. Some technicians have seen this liquefied grease and thought is was power steering fluid. Gears should not be replaced for this condition. If the customer indicates that they have seen what they think was a leak, resembling oil residue, on their garage floor or driveway, or the technician sees Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Fluid: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise > Page 6686 drops of oil leaking, carefully inspect the power steering hydraulic system. The inspection should be performed while the engine is running and the steering wheel is rotated from lock to lock. If a leak is observed, then repair the source of the leak. If the noise is not the result of low power steering fluid, provide a complete description of when the noise happens and what type of noise it is; i.e. squeal, pop, clunk, tick, continuous rubbing, etc. If it is a pop or clunk noise, make sure you inspect the convoluted boots to determine if the inner tie rod is rubbing the boots. Replace the boot or boots only for this condition. If the noise is a clunk or pop noise and it's not the inner tie rod rubbing the convoluted boots, make sure to inspect the intermediate shaft for the slip stick condition. This should be done prior to replacing any steering gears. If amber/yellow tinted glasses and the "pen light" style of black light are used, the lithium in the grease will show up in greenish/yellow similar to the greenish/yellow dye used by many dealerships to test for leaks. Always use the black light recommended by GM Tools and clear glasses to inspect for dye in fluid leaks. If the source of the leak cannot be found by visual inspection, add dye, P/N 88861206 (in Canada, use P/N 88861259), and inspect the system using Black Light (J 28428-E or J 42220). The number of vehicles that will require a complete inspection using dye will be minimal based on the inspection of numerous steering gears returned for testing where the complaint was fluid leak and no leaks could be reproduced. If a steering gear is replaced because a leak was discovered using the dye test method, make sure the repair order has a description of where the leak was discovered. If the steering gear is replaced for a noise concern, make sure a complete description of the diagnosis appears on the repair order as described in Step 5 above. Steering gears replaced under warranty will continue to be on parts return and regional feedbacks will be processed on any gears which the customer complaint cannot be verified. Over 90% of all steering gears inspected have little or no explanation of the condition, the technician's diagnosis or reason for replacing the gears and/or did not have any indication that dye was used to find a leak. Parts Information Warranty Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Technical Service Bulletins > All Other Service Bulletins for Power Steering Fluid: > 06-02-32-009B > Nov > 08 > Steering - Noise Diagnostics TSB References Power Steering Fluid: All Technical Service Bulletins Steering - Noise Diagnostics TSB References INFORMATION Bulletin No.: 06-02-32-009B Date: November 19, 2008 Subject: Overview of Steering System Noises Models: 2001-2004 Buick Regal 2001-2005 Buick Century 2005-2007 Buick Allure (Canada Only), LaCrosse 2000-2006 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 1998-2002 Oldsmobile Intrigue 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to remove reference to Corporate Bulletin Number 01-02-32-001 from the table below. Please discard Corporate Bulletin Number 06-02-32-009A (Section 02 - Steering). The purpose of this bulletin is to provide a quick reference for dealers to aid in locating the correct service bulletin for several different steering system noise concerns. Many customer concerns with the steering system involve specific symptoms (noises heard). Once the customer concern has been verified, the table above may help identify the correct bulletin to reference. If other symptoms are present, or if diagnosis indicates another cause not found in any of the three service bulletins, refer to SI to diagnose the repair customer concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications Power Steering Fluid: Capacity Specifications Power Steering Fluid ........................................................................................................................... .................................................... 1.1 pints (1.0 liters) NOTE: ALL capacity specifications are approximate. When replacing or adding fluids, fill to the recommended level and recheck fluid level. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component Information > Specifications > Capacity Specifications > Page 6694 Power Steering Fluid: Fluid Type Specifications POWER STEERING SYSTEM GM Power Steering Fluid GM P/N 89021184 (Canadian P/N 89021186) or equivalent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications Power Steering Fluid Cooler: Specifications Power Steering Cooler Retaining Nuts .................................................................................................................................................. 14 Nm (124 in. lbs.) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Cooler > Component Information > Specifications > Page 6698 Power Steering Fluid Cooler: Service and Repair Power Steering Cooler Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Place a drain pan under the vehicle. 3. Remove the power steering cooler hoses from the power steering cooler. 4. Remove the bolts from the power steering cooler. 5. Remove the power steering cooler from the vehicle. Installation Procedure 1. Install the power steering cooler to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the power steering cooler. ^ Tighten the retaining bolts to 14 Nm (124 in. lbs.). 3. Install the power steering cooler hoses. 4. Bleed the power steering system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir > Component Information > Service and Repair Power Steering Fluid Reservoir: Service and Repair Power Steering Reservoir Replacement - Off Vehicle (CB Series) Disassembly Procedure 1. Place the hydraulic pump (1) on a fixed, flat surface, with the shaft facing upward. 2. Insert a screwdriver into the retaining clip tab (3). 3. Using the screwdriver, force the retaining clip tab (3) outward. 4. Slide the reservoir clip (4) away from the hydraulic pump assembly (1). 5. Repeat the above steps to remove the second reservoir clip (4). 6. Remove the reservoir (2) from the hydraulic pump housing (1). 7. Remove the O-ring seal from the neck of the reservoir (2) or inside the hydraulic pump housing (1). Discard the O-ring seal. Assembly Procedure 1. Lubricate the new O-ring seal with power steering fluid. 2. Install the new O-ring seal onto the neck of the reservoir (2). 3. Install the reservoir (2) onto the hydraulic pump assembly (1). Ensure the reservoir neck is completely engaged onto the hydraulic pump assembly (1). 4. Align the feet of the reservoir with the sides of the hydraulic pump housing. 5. Install the new reservoir retaining clips (4) (supplied with the pump). Ensure the retaining clip tabs (3) fully engage with the hydraulic pump housing (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise Power Steering Line/Hose: Customer Interest Steering - Steering Gear Leaks/Moan or Groan Noise Bulletin No.: 05-02-32-007D Date: March 29, 2007 ENGINEERING INFORMATION Subject: EI05119 - Power Steering Gear Leak, Moan, Groan or Whine Noise (Diagnose and Repair as Necessary) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2004-2007 Chevrolet Impala, Monte Carlo 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to provide additional leak and noise diagnosis information. Please discard Corporate Bulletin Number 05-02-32-007C (Section 02 - Steering). Condition Some customers may comment on a power steering gear leak or that the gear appears to be leaking. Additionally, the customer may come into the dealership indicating they were told by an aftermarket service facility that the steering gear was leaking because the power steering reservoir was low on fluid and the gear showed an oil residue. Some customers may also comment on a power steering noise during steering maneuvers or while driving. Correction Inspect and diagnose the power steering system before any repairs are attempted using the procedure listed below. Because the power steering reservoir on 3800 V6-equipped vehicles is located behind and below the rear cylinder head, the fluid level may not be getting checked and/or topped off similar to other vehicles which have a reservoir that is located on the upper portion of the engine. This condition could be more prevalent with vehicles serviced at non-GM dealerships. Determine if the power steering system is full of oil. Adjust the fluid in the reservoir to the proper level. The lower fluid level could be the result of a variation in the original system fill. Plus, over time and mileage, the system purges any remaining air. Additionally, as the hoses expand and contract, the fluid level may drop as measured within the reservoir. Don't assume there is an external fluid leak just because the fluid level in the reservoir is down to the Add mark. Restart the engine and see if the noise goes away after turning the steering wheel lock to lock a few times. This will correct most, if not all, the vehicles with a noise condition. If the customer was told their was a power steering fluid leak by an aftermarket service facility because the power steering reservoir needed fluid and they saw oil residue on the power steering gear, then carefully inspect the gear and surrounding area for oil residue. Below are some causes as to why oil residue may be present. Oil residue on the body of the steering gear usually on the pinion area (left side) of the gear or on the convoluted boots. This condition could be caused by a small amount of oil that can drip out when the shipping plugs are removed from the gear, just prior to the installation of the P/S pressure and return lines being connected at the assembly plants. Gears should not be replaced for this condition. Oil residue on or near the pinion adjuster nut plug. During the gear assembly process the supplier uses grease to lubricate the pinion adjuster plug threads. In cases where a lot of grease was used on the adjuster plug threads, some grease can ooze out around the threads and when mixed with moisture and road grime, it can appear as though the plug is leaking. In some cases the heat generated from the exhaust system will start to liquefy some of the grease and cause it to run. Gears should not be replaced for this condition. Oil residue inside the convoluted boots. When the steering gear is assembled into the housing, grease is applied to the gear teeth. In some cases, if there is a lot of grease used, it will squeeze out of the gear teeth, soften and run down and collect in the bottom of the convolutes. This may have the appearance of a thick oil, especially in hot climates. Some technicians have seen this liquefied grease and thought is was power steering fluid. Gears should not be replaced for this condition. If the customer indicates that they have seen what they think was a leak, resembling oil residue, on their garage floor or driveway, or the technician sees Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise > Page 6710 drops of oil leaking, carefully inspect the power steering hydraulic system. The inspection should be performed while the engine is running and the steering wheel is rotated from lock to lock. If a leak is observed, then repair the source of the leak. If the noise is not the result of low power steering fluid, provide a complete description of when the noise happens and what type of noise it is; i.e. squeal, pop, clunk, tick, continuous rubbing, etc. If it is a pop or clunk noise, make sure you inspect the convoluted boots to determine if the inner tie rod is rubbing the boots. Replace the boot or boots only for this condition. If the noise is a clunk or pop noise and it's not the inner tie rod rubbing the convoluted boots, make sure to inspect the intermediate shaft for the slip stick condition. This should be done prior to replacing any steering gears. If amber/yellow tinted glasses and the "pen light" style of black light are used, the lithium in the grease will show up in greenish/yellow similar to the greenish/yellow dye used by many dealerships to test for leaks. Always use the black light recommended by GM Tools and clear glasses to inspect for dye in fluid leaks. If the source of the leak cannot be found by visual inspection, add dye, P/N 88861206 (in Canada, use P/N 88861259), and inspect the system using Black Light (J 28428-E or J 42220). The number of vehicles that will require a complete inspection using dye will be minimal based on the inspection of numerous steering gears returned for testing where the complaint was fluid leak and no leaks could be reproduced. If a steering gear is replaced because a leak was discovered using the dye test method, make sure the repair order has a description of where the leak was discovered. If the steering gear is replaced for a noise concern, make sure a complete description of the diagnosis appears on the repair order as described in Step 5 above. Steering gears replaced under warranty will continue to be on parts return and regional feedbacks will be processed on any gears which the customer complaint cannot be verified. Over 90% of all steering gears inspected have little or no explanation of the condition, the technician's diagnosis or reason for replacing the gears and/or did not have any indication that dye was used to find a leak. Parts Information Warranty Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise Power Steering Line/Hose: All Technical Service Bulletins Steering - Steering Gear Leaks/Moan or Groan Noise Bulletin No.: 05-02-32-007D Date: March 29, 2007 ENGINEERING INFORMATION Subject: EI05119 - Power Steering Gear Leak, Moan, Groan or Whine Noise (Diagnose and Repair as Necessary) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2004-2007 Chevrolet Impala, Monte Carlo 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to provide additional leak and noise diagnosis information. Please discard Corporate Bulletin Number 05-02-32-007C (Section 02 - Steering). Condition Some customers may comment on a power steering gear leak or that the gear appears to be leaking. Additionally, the customer may come into the dealership indicating they were told by an aftermarket service facility that the steering gear was leaking because the power steering reservoir was low on fluid and the gear showed an oil residue. Some customers may also comment on a power steering noise during steering maneuvers or while driving. Correction Inspect and diagnose the power steering system before any repairs are attempted using the procedure listed below. Because the power steering reservoir on 3800 V6-equipped vehicles is located behind and below the rear cylinder head, the fluid level may not be getting checked and/or topped off similar to other vehicles which have a reservoir that is located on the upper portion of the engine. This condition could be more prevalent with vehicles serviced at non-GM dealerships. Determine if the power steering system is full of oil. Adjust the fluid in the reservoir to the proper level. The lower fluid level could be the result of a variation in the original system fill. Plus, over time and mileage, the system purges any remaining air. Additionally, as the hoses expand and contract, the fluid level may drop as measured within the reservoir. Don't assume there is an external fluid leak just because the fluid level in the reservoir is down to the Add mark. Restart the engine and see if the noise goes away after turning the steering wheel lock to lock a few times. This will correct most, if not all, the vehicles with a noise condition. If the customer was told their was a power steering fluid leak by an aftermarket service facility because the power steering reservoir needed fluid and they saw oil residue on the power steering gear, then carefully inspect the gear and surrounding area for oil residue. Below are some causes as to why oil residue may be present. Oil residue on the body of the steering gear usually on the pinion area (left side) of the gear or on the convoluted boots. This condition could be caused by a small amount of oil that can drip out when the shipping plugs are removed from the gear, just prior to the installation of the P/S pressure and return lines being connected at the assembly plants. Gears should not be replaced for this condition. Oil residue on or near the pinion adjuster nut plug. During the gear assembly process the supplier uses grease to lubricate the pinion adjuster plug threads. In cases where a lot of grease was used on the adjuster plug threads, some grease can ooze out around the threads and when mixed with moisture and road grime, it can appear as though the plug is leaking. In some cases the heat generated from the exhaust system will start to liquefy some of the grease and cause it to run. Gears should not be replaced for this condition. Oil residue inside the convoluted boots. When the steering gear is assembled into the housing, grease is applied to the gear teeth. In some cases, if there is a lot of grease used, it will squeeze out of the gear teeth, soften and run down and collect in the bottom of the convolutes. This may have the appearance of a thick oil, especially in hot climates. Some technicians have seen this liquefied grease and thought is was power steering fluid. Gears should not be replaced for this condition. If the customer indicates that they have seen what they think was a leak, resembling oil residue, on their garage floor or driveway, or the technician sees Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 05-02-32-007D > Mar > 07 > Steering - Steering Gear Leaks/Moan or Groan Noise > Page 6716 drops of oil leaking, carefully inspect the power steering hydraulic system. The inspection should be performed while the engine is running and the steering wheel is rotated from lock to lock. If a leak is observed, then repair the source of the leak. If the noise is not the result of low power steering fluid, provide a complete description of when the noise happens and what type of noise it is; i.e. squeal, pop, clunk, tick, continuous rubbing, etc. If it is a pop or clunk noise, make sure you inspect the convoluted boots to determine if the inner tie rod is rubbing the boots. Replace the boot or boots only for this condition. If the noise is a clunk or pop noise and it's not the inner tie rod rubbing the convoluted boots, make sure to inspect the intermediate shaft for the slip stick condition. This should be done prior to replacing any steering gears. If amber/yellow tinted glasses and the "pen light" style of black light are used, the lithium in the grease will show up in greenish/yellow similar to the greenish/yellow dye used by many dealerships to test for leaks. Always use the black light recommended by GM Tools and clear glasses to inspect for dye in fluid leaks. If the source of the leak cannot be found by visual inspection, add dye, P/N 88861206 (in Canada, use P/N 88861259), and inspect the system using Black Light (J 28428-E or J 42220). The number of vehicles that will require a complete inspection using dye will be minimal based on the inspection of numerous steering gears returned for testing where the complaint was fluid leak and no leaks could be reproduced. If a steering gear is replaced because a leak was discovered using the dye test method, make sure the repair order has a description of where the leak was discovered. If the steering gear is replaced for a noise concern, make sure a complete description of the diagnosis appears on the repair order as described in Step 5 above. Steering gears replaced under warranty will continue to be on parts return and regional feedbacks will be processed on any gears which the customer complaint cannot be verified. Over 90% of all steering gears inspected have little or no explanation of the condition, the technician's diagnosis or reason for replacing the gears and/or did not have any indication that dye was used to find a leak. Parts Information Warranty Information Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Pressure Hose Power Steering Line/Hose: Service and Repair Pressure Hose Power Steering Pressure Pipe/Hose Replacement (3.8L) Removal Procedure 1. Place a drain pan under the vehicle. 2. Remove the accessory drive belt. 3. Raise and support the vehicle. Refer to Vehicle Lifting. 4. Remove the tire and wheel assembly. 5. The power steering pressure hose is the lower hose at the power steering gear. Remove the power steering pressure hose from the power steering gear. 6. Remove the power steering pressure hose from the power steering pump. 7. Remove the power steering pressure hose from the clamps on the power steering gear. 8. Remove the power steering pressure hose from the vehicle. Installation Procedure 1. Install the power steering pressure hose to the vehicle. 2. Install the power steering pressure hose to the clamps on the power steering gear. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the power steering pressure hose to the power steering pump. ^ Tighten the fitting to 27 Nm (20 ft. lbs.). 4. Install the power steering pressure hose to the power steering gear. ^ Tighten the pressure hose fitting to 27 Nm (20 ft. lbs.). 5. Install the tire and wheel assembly. 6. Remove the drain pan from under the vehicle. 7. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Pressure Hose > Page 6719 8. Install the accessory drive belt. 9. Fill the power steering system with power steering fluid. 10. Bleed the power steering system. 11. Inspect the power steering system for leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Pressure Hose > Page 6720 Power Steering Line/Hose: Service and Repair Return Hose Power Steering Return Hose Replacement (3.8L) Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the power steering return hose (2) from the power steering gear (1). 4. Remove the return hose (2) from the clips on the power steering gear. 5. Remove the return hose (1) from the power steering pump. 6. Remove the return hose (1) from the hose retainers (3) on the cradle (4). 7. Disconnect the clips and the electrical harnesses from the return hose (1). 8. Remove the return hose (1) from the vehicle. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Pressure Hose > Page 6721 1. Install the return hose (1) to the vehicle. 2. Connect the clips and the electrical harnesses to the return hose (1). 3. Install the return hose (1) to the hose retainers (3) on the cradle (4). 4. Install the return hose (1) to the power steering pump. 5. Install the return hose (2) to the clips on the power steering gear. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the return hose (1) to the power steering gear (1). ^ Tighten the fitting to 27 Nm (20 ft. lbs.). 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Fill the power steering fluid reservoir. 10. Bleed the power steering system. 11. Inspect the power steering system for leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Pressure Hose > Page 6722 Power Steering Line/Hose: Service and Repair Power Steering Cooler Pipe/Hose Replacement Power Steering Cooler Pipe/Hose Replacement Removal Procedure 1. Remove the engine mount struts from the engine. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. 4. Place a drain pan under the vehicle. Notice: The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly. 5. Remove the intermediate steering shaft from the power steering gear stub shaft. 6. Use a utility stand in order to support the frame. 7. Remove the frame bolts from the rear of the frame. Notice: Do not lower the rear of the frame too far as damage to the engine components nearest to the cowl may result. 8. Use the utility stand in order to lower the rear of the frame to gain access. 9. Remove the power steering return hose from the power steering pump to the power steering cooler pipe. 10. Remove the power steering return line from the power steering gear. 11. Remove the power steering return line from the clamp on the power steering gear. 12. Remove the power steering cooler pipe retaining clips. 13. Remove the power steering cooler pipe from the vehicle. Installation Procedure 1. Install the power steering cooler pipe to the vehicle. 2. Install the power steering cooler pipe retaining clips. 3. Install the power steering return line to the power steering gear. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Service and Repair > Pressure Hose > Page 6723 4. Install the power steering return line to the clamp on the power steering gear. 5. Install the power steering return hose from the power steering pump to the power steering cooler pipe. 6. Use the utility stand in order to raise the frame. 7. Install NEW frame bolts to the rear of the frame. 8. Install the intermediate steering shaft to the power steering gear stub shaft. 9. Install the tire and wheel assembly. 10. Remove the drain pan from under the vehicle. 11. Lower the vehicle. 12. Install the engine mount struts to the engine. 13. Fill the power steering fluid reservoir. 14. Bleed the power steering system. 15. Inspect the power steering system for leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Motor > Component Information > Technical Service Bulletins > Steering - Power Steering Pump Replacement Tips Power Steering Motor: Technical Service Bulletins Steering - Power Steering Pump Replacement Tips INFORMATION Bulletin No.: 06-02-32-013B Date: August 07, 2009 Subject: Diagnostic Tips/Recommendations When Power Steering Pump Replacement is Necessary Models: 1997-2010 GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and update the information. Please discard Corporate Bulletin Number 06-02-32-013A (Section 02 - Steering). A recently completed analysis of returned power steering (PS) pumps that had been replaced for noise, no power assist, no or low pressure and leaking conditions has indicated a high number of "No Trouble Found" results. Corporate Bulletin Number 01-02-32-004 indicates that when attempting to repair a power steering concern, the steering system analyzer should be utilized to assist the technician in a successful diagnosis. Note- Saturn ASTRA does not utilize the Power Steering System Analyzer. In addition, extensive warranty analysis has shown that the following situations are all significant root causes of PS pump failures: - Improper pulley installation - Re-using the O-rings - Using fluid other than the OE-specified steering fluid - Failure to flush the PS system In order to help improve customer satisfaction and reduce comebacks, GM recommends the following tips for replacing a PS pump: 1. Low or no pressure from the PS pump may be the results of dirty or contaminated fluid, which could cause the pressure relief valve to stop functioning. Using the proper tools, flush and bleed the PS system. Any residual contaminants will result in pump failure. 2. When removing the pulley, use the proper special tools. Because the pulley alignment is critical, distorting the pulley may damage bearings on the new PS pump. Note Some new PS pumps may not include a new O-ring. Please refer to the appropriate Parts Catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle. 3. Be sure to use only the new O-rings included with the PS pump. The new reservoir O-ring must be lubricated with OE-specific PS fluid prior to installation. Also make sure that the control valve O-ring is in its exact groove position and is NOT covering the pressure bypass hole. 4. Bleed the PS system according to the procedures/recommendations in SI. Following these procedures and using the correct tools and fluids should help ensure that the new PS pump operates properly. Skipping steps may cost you time and trouble later. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Service and Repair Power Steering Pressure Control Valve: Service and Repair Power Steering Pump Flow Control Valve Replacement - Off Vehicle (CB Series) Disassembly Procedure 1. Remove the O-ring union fitting (5) from the hydraulic pump housing assembly (1). 2. Remove the O-ring seal (4) from the O-ring union fitting (5). 3. Remove the control valve assembly (3). 4. Remove the flow control spring (2). Assembly Procedure 1. Install the flow control spring (2) to the hydraulic pump housing assembly (1). 2. Install the control valve assembly (3). 3. Lubricate the O-ring seal (4) with power steering fluid. 4. Install the O-ring seal (4) onto the O-ring union fitting (5). Notice: Refer to Fastener Notice in Service Precautions. 5. Install the O-ring union fitting (5) into the hydraulic pump housing assembly (1). ^ Tighten the fitting (5) to 75 Nm (55 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications Power Steering Pump Specifications Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6734 Power Steering Pump Disassembled View (CB Series Pump) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley Power Steering Pump: Service and Repair Power Steering Pulley Power Steering Pulley Replacement ^ Tools Required J 25033-C Power Steering Pump Pulley Installer - J 25034-C Power Steering Pump Pulley Remover Removal Procedure 1. Remove the power steering pump assembly from the vehicle. 2. Using J 25034-C remove the power steering pump pulley from the power steering pump. Installation Procedure Important: ^ Never use a hammer to install the power steering pulley. ^ Do not use an arbor press to install the power steering pulley. ^ The face of the pulley hub must be flush with the end of the pump driveshaft. 1. Using J25033-C install the power steering pump pulley to the power steering pump. 2. Install the power steering pump assembly to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 6737 Power Steering Pump: Service and Repair Power Steering Pump Replacement Power Steering Pump Replacement (3.8L) Removal Procedure 1. Remove the accessory drive belt. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. 4. Remove the power steering pressure hose from the power steering pump. 5. Remove the power steering return hose from the power steering pump. 6. Remove the electrical connector (4) from the power steering pump (1). 7. Remove the power steering mounting bolts from the power steering pump. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 6738 8. Remove the power steering pump. 9. Remove the power steering pump reservoir from the power steering pump. 10. Remove the power steering pump pulley from the power steering pump. Installation Procedure 1. Install the power steering pump reservoir to the power steering pump. 2. Install the power steering pump pulley to the power steering pump. 3. Position the power steering pump to the engine. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the power steering pump mounting bolts. ^ Tighten the mounting bolts to 34 Nm (25 ft. lbs.). 5. Install the power steering pressure hose to the power steering pump. 6. Install the power steering return hose to the power steering pump. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Power Steering Pulley > Page 6739 7. Install the electrical connector (1) to the power steering pump (4). 8. Install the accessory drive belt. 9. Fill the power steering system with fluid. 10. Bleed the power steering system. 11. Inspect the power steering system for leaks. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Disabling And Enabling Zones Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6745 The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6746 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the radiator upper air baffle and deflector. 7. Remove the orange connector position assurance (CPA) (2) from the yellow sensor harness connector (3). 8. Disconnect the sensor harness connector from the sensor (1). Zone 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6747 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the side impact sensor (SIS)-LF from the center pillar. 7. Remove the connector position assurance (CPA) from the SIS-LF connector (2). 8. Disconnect the SIS-LF connector (2) from the SIS-LF (1). Zone 3 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6748 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the LH insulator panel. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Disconnect the steering wheel module coil connector. Zone 5 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6749 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the RH IP access hole cover. 7. Remove the connector position assurance (CPA) from the inflatable restraint IP module connector located to the right of the steering column. 8. Disconnect the IP module connector. Zone 7 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6750 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the fuse block access cover. 5. Remove the SIR Fuse. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the side impact module - LF connector (1) located under the driver seat. 7. Disconnect the side impact module - LF connector (1). Zone 9 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6751 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the I/P fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the LH insulator panel. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Disconnect the steering wheel module coil connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6752 9. Remove the RH I/P access hole cover. 10. Remove the CPA from the inflatable restraint I/P module connector, located at the RH side of the I/P. 11. Disconnect the I/P module connector. 12. Remove the CPA from the inflatable restraint side impact module - LF connector (1), located under the driver seat. 13. Disconnect the side impact module - LF connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6753 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition. 2. Connect the sensor harness connector (3) to the sensor (1). 3. Install the orange CPA (2) into the yellow sensor harness connector (3). 4. Install the radiator upper air baffle and deflector. 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash seven times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6754 1. Connect the SIS-LF connector (2) to the SIS-LF (1). 2. Install the CPA to the SIS-LF connector(2). 3. Install the side impact sensor (SIS)-LF into the center pillar. 4. Install the SIR Fuse. 5. Install the fuse block access cover. 6. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. 2. Connect the steering wheel module coil connector. 3. Install the CPA from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 4. Install the LH insulator panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6755 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash seven times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the IP module connector. 3. Install the CPA into the IP module connector located to the right of the steering column. 4. Install the LH insulator panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6756 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Connect the inflatable restraint side impact module - LF connector (1) located under the driver seat. 2. Install the CPA to the side impact module - LF connector (1). 3. Remove the SIR Fuse. 4. Install the fuse block access cover. 5. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 5.1. The AIR BAG indicator will flash seven times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6757 1. Remove the key from the ignition. Connect the inflatable restraint side impact module - LF connector (1), located under the driver seat. 2. Install the CPA to the side impact module - LF connector. 3. Connect the inflatable restraint I/P module connector, located at the RH side of the I/P. 4. Install the CPA to the I/P module connector. 5. Install the RH I/P access hole cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 6758 6. Connect the steering wheel module coil connector. 7. Install the CPA from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Install the LH insulator panel. 9. Install the SIR Fuse. 10. Install the LH I/P access hole cover. 11. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 11.1. The AIR BAG indicator will flash seven times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Steering Gear Pinion Shaft > Component Information > Technical Service Bulletins > Steering - Noise Diagnostics TSB References Steering Gear Pinion Shaft: Technical Service Bulletins Steering - Noise Diagnostics TSB References INFORMATION Bulletin No.: 06-02-32-009B Date: November 19, 2008 Subject: Overview of Steering System Noises Models: 2001-2004 Buick Regal 2001-2005 Buick Century 2005-2007 Buick Allure (Canada Only), LaCrosse 2000-2006 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 1998-2002 Oldsmobile Intrigue 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to remove reference to Corporate Bulletin Number 01-02-32-001 from the table below. Please discard Corporate Bulletin Number 06-02-32-009A (Section 02 - Steering). The purpose of this bulletin is to provide a quick reference for dealers to aid in locating the correct service bulletin for several different steering system noise concerns. Many customer concerns with the steering system involve specific symptoms (noises heard). Once the customer concern has been verified, the table above may help identify the correct bulletin to reference. If other symptoms are present, or if diagnosis indicates another cause not found in any of the three service bulletins, refer to SI to diagnose the repair customer concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions Steering Mounted Controls Transmitter: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6768 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6769 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6770 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6771 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6772 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6773 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6774 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6775 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6776 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6777 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6778 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6779 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6780 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6781 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6782 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6783 Steering Mounted Controls Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6784 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6785 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6786 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6787 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6788 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6789 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6790 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6791 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6792 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6793 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6794 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6795 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6796 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6797 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6798 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6799 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6800 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6801 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6802 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6803 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6804 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6805 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6806 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6807 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6808 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6809 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6810 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 6811 Steering Mounted Controls Transmitter: Electrical Diagrams Steering Wheel Controls Diagram Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 6812 Steering Mounted Controls Transmitter: Service and Repair Steering Wheel Control Switch Assembly Replacement (Impala) Removal Procedure 1. Disable the SIR system. 2. Remove the inflatable restraint steering wheel module. 3. Remove the steering wheel. 4. Remove the steering wheel controls wire harness from the retainers in the aluminum insert and plastic back shroud. 5. Remove the back shroud screws and the back shroud on the back of the steering wheel. 6. Carefully push on the back of the steering wheel radio control switch through the access opening in the back of the steering wheel switch pocket. 7. Disconnect the electrical connector from the back of the steering wheel radio control switch. 8. Remove the radio control switch from the steering wheel. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 6813 1. Position the radio control switch to the steering wheel. Route the radio control wire harness through the access opening in the back of the steering wheel switch pocket. 2. Connect the electrical connector to the back of the steering wheel radio control switch. 3. Carefully install the radio control switch into the steering wheel switch pocket. Important: The steering wheel switch wiring harness must be kept below the white insulators on the back of the steering wheel when installing the plastic back shroud. Do not pinch the wire harness between the steering wheel urethane and the plastic back shroud. 4. Install the plastic back shroud to the back of the steering wheel with the shroud screws. 5. Install the radio controls wiring harness to the retainers in the steering wheel insert and back shroud. Verify that the wiring is not routed underneath any of the four SIR module mounting holes in the steering wheel. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the shroud screws and the shroud on the back of the steering wheel. ^ Tighten the screws to 2 Nm (18 in. lbs.). 7. Install the steering wheel. 8. Install the inflatable restraint steering wheel module. 9. Enable the SIR system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 01-02-32-001P > Nov > 09 > Steering - Steering Column Clunking When Turning Steering Shaft: Customer Interest Steering - Steering Column Clunking When Turning TECHNICAL Bulletin No.: 01-02-32-001P Date: November 25, 2009 Subject: Clunk Felt/Noise Heard From Steering Column, Steering Gear and/or Front Of Vehicle During Turning Maneuver and/or Steering Wheel Rotation (Replace Intermediate Shaft As Directed) Models: 2001-2004 Buick Regal 2005-2008 Buick Allure (Canada Only), LaCrosse 2000-2008 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 1998-2002 Oldsmobile Intrigue 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to add the 2008 Buick LaCrosse/Allure. Please discard Corporate Bulletin Number 01-02-32-001O (Section 02 - Steering). Condition Some customers may comment on a clunk type noise coming from the front of the vehicle while driving during a turning maneuver. This condition may also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Some vehicles may only exhibit the noise once for every 360° of wheel rotation. On all other vehicles, this clunk noise will be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel or when applying/releasing the brakes. Cause This condition may be caused by a "slip stick" condition of the steering intermediate shaft resulting in the clunk noise or feel through the steering wheel. Diagnostic Tip Important This condition is commonly misdiagnosed as originating in the steering gear and has resulted in the replacement of numerous steering gears without correcting the concern. Attempt to duplicate the customer's concern and isolate the I-shaft by following the procedure below: 1. Locate a large area (parking lot) where the vehicle can be turned in a tight circle. 2. Turn the steering wheel to the right and/or left all the way to the steering lock, then off the steering lock a 1/4 turn. 3. Drive the vehicle approximately 5 km/h (3 mph) in a circle, preferably over rough pavement or seams on the road surface. 4. Drive the vehicle straight ahead at idle speed while applying and releasing the brake pedal. Listen/feel the steering wheel for the clunk/noise condition. 5. If a clunk is felt in the steering wheel, the MOST likely cause is the I-shaft - not the steering gear. Continue with the correction. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > Customer Interest for Steering Shaft: > 01-02-32-001P > Nov > 09 > Steering - Steering Column Clunking When Turning > Page 6822 Correction Replace the existing intermediate shaft using the service procedure found in Service Information. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 01-02-32-001P > Nov > 09 > Steering - Steering Column Clunking When Turning Steering Shaft: All Technical Service Bulletins Steering - Steering Column Clunking When Turning TECHNICAL Bulletin No.: 01-02-32-001P Date: November 25, 2009 Subject: Clunk Felt/Noise Heard From Steering Column, Steering Gear and/or Front Of Vehicle During Turning Maneuver and/or Steering Wheel Rotation (Replace Intermediate Shaft As Directed) Models: 2001-2004 Buick Regal 2005-2008 Buick Allure (Canada Only), LaCrosse 2000-2008 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 1998-2002 Oldsmobile Intrigue 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to add the 2008 Buick LaCrosse/Allure. Please discard Corporate Bulletin Number 01-02-32-001O (Section 02 - Steering). Condition Some customers may comment on a clunk type noise coming from the front of the vehicle while driving during a turning maneuver. This condition may also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Some vehicles may only exhibit the noise once for every 360° of wheel rotation. On all other vehicles, this clunk noise will be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel or when applying/releasing the brakes. Cause This condition may be caused by a "slip stick" condition of the steering intermediate shaft resulting in the clunk noise or feel through the steering wheel. Diagnostic Tip Important This condition is commonly misdiagnosed as originating in the steering gear and has resulted in the replacement of numerous steering gears without correcting the concern. Attempt to duplicate the customer's concern and isolate the I-shaft by following the procedure below: 1. Locate a large area (parking lot) where the vehicle can be turned in a tight circle. 2. Turn the steering wheel to the right and/or left all the way to the steering lock, then off the steering lock a 1/4 turn. 3. Drive the vehicle approximately 5 km/h (3 mph) in a circle, preferably over rough pavement or seams on the road surface. 4. Drive the vehicle straight ahead at idle speed while applying and releasing the brake pedal. Listen/feel the steering wheel for the clunk/noise condition. 5. If a clunk is felt in the steering wheel, the MOST likely cause is the I-shaft - not the steering gear. Continue with the correction. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Steering Shaft: > 01-02-32-001P > Nov > 09 > Steering - Steering Column Clunking When Turning > Page 6828 Correction Replace the existing intermediate shaft using the service procedure found in Service Information. Parts Information Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement Steering Shaft: Service and Repair Intermediate Steering Shaft Replacement Intermediate Steering Shaft Replacement ^ Tools Required J 42640 Steering Column Anti-Rotation Pin Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Install J 42640 into the bottom of the steering column. 4. Position the intermediate steering shaft seal in order to provide access to the lower pinch bolt. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement > Page 6831 Notice: The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly. 5. Remove the lower pinch bolt from the power steering gear stub shaft (2). 6. Remove the intermediate steering shaft (1) from the power steering gear stub shaft (2). 7. Lower the vehicle. 8. Remove the left instrument panel insulator. 9. Reposition the intermediate steering shaft seal in order to gain access to the upper pinch bolt. 10. Remove the upper pinch bolt from the intermediate steering shaft. 11. Disconnect the intermediate steering shaft from the steering column. 12. Remove the intermediate steering shaft. Installation Procedure 1. Position the intermediate steering shaft into place. Notice: Refer to Fastener Notice in Service Precautions 2. Install the upper pinch bolt which secures the intermediate steering shaft to the steering column. ^ Tighten the pinch bolt to 48 Nm (35 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement > Page 6832 3. Install the intermediate steering shaft seal onto the steering column. 4. Raise and support the vehicle. Refer to Vehicle Lifting. 5. Install the intermediate steering shaft (1) to the power steering gear stub shaft (2). 6. Install the lower pinch bolt which secures the intermediate steering shaft to the power steering gear stub shaft. ^ Tighten the pinch bolt to 48 Nm (35 ft. lbs.). 7. Remove the J 42640 from the steering column. 8. Install the intermediate steering shaft seal onto the power steering gear. 9. Install the tire and wheel assembly. 10. Lower the vehicle. 11. Install the left instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Intermediate Steering Shaft Replacement > Page 6833 Steering Shaft: Service and Repair Seal Replacement - Intermediate Steering Shaft Seal Replacement - Intermediate Steering Shaft Removal Procedure 1. Turn the ignition OFF and remove the key from the ignition lock cylinder in order to lock the steering column. 2. Remove the intermediate shaft seal from the steering column. 3. Disconnect the intermediate shaft from the steering column. 4. Push the intermediate shaft down in order to collapse the intermediate shaft. 5. Remove the intermediate shaft seal bolts. Important: It may be necessary to remove the lower portion of the intermediate shaft seal from the steering gear. 6. Remove the intermediate shaft seal. Installation Procedure 1. Install the intermediate shaft lower seal over the intermediate shaft and to the steering gear. 2. Install the intermediate shaft upper seal over the lower seal and to the instrument panel. 3. Connect the intermediate shaft to the steering column. 4. Install the intermediate shaft seal to the steering column. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the intermediate shaft seal bolts. ^ Tighten the intermediate shaft seal bolts to 3 Nm (27 in. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications Steering Wheel: Specifications Steering Wheel Nut ............................................................................................................................. ..................................................... 45 Nm (33 ft. lbs.) Steering Wheel Shroud Screws ....................... ............................................................................................................................................ 2 Nm (18 ft. lbs.) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 6837 Steering Wheel: Description and Operation Steering Wheel and Column Description and Operation The steering wheel and column has 4 primary functions: ^ Vehicle steering ^ Vehicle security ^ Driver convenience ^ Driver safety Vehicle Steering The steering wheel is the first link between the driver and the vehicle. The steering wheel is fastened to a steering shaft within the column. At the lower end of the column, the intermediate shaft connects the column to the steering gear. Vehicle Security - Some Vehicle Models Theft deterrent components are mounted and designed into the steering column. The following components allow the column to be locked in order to minimize theft: ^ The ignition switch assembly ^ The steering column lock ^ The ignition cylinder Driver Convenience The steering wheel and column may also have driver controls attached for convenience and comfort. The following controls may be mounted on or near the steering wheel or column. ^ The turn signal switch ^ The hazard switch ^ The headlamp dimmer switch ^ The wiper/washer switch ^ The horn pad/cruise control switch ^ The redundant radio/entertainment system controls ^ The tilt or tilt/telescoping functions ^ The navigation/OnStar- features ^ The HVAC controls Driver Safety The energy-absorbing steering column compresses in the event of a front-end collision, which reduces the chance of injury to the driver. The mounting capsules break away from the mounting bracket in the event of an accident. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 6838 Steering Wheel: Service and Repair Steering Wheel Replacement ^ Tools Required J 1859-A Steering Wheel Puller - J 42578 Steering Wheel Puller Legs Removal Procedure 1. Disable the SIR system. 2. Turn OFF the ignition. 3. Remove the Inflatable restraint steering wheel module. 4. Scribe an alignment mark on the steering wheel hub. Align the mark with the slash mark on the steering shaft. 5. Loosen the steering wheel nut. 6. Position the steering wheel nut flush with the end of the steering shaft. 7. Assemble J 1859-A with J 42578 on the steering wheel. 8. Use J 1859-A with J 42578 in order to unseat the steering wheel from the steering shaft. 9. Remove J 1859-A and J 42578 from the steering wheel. 10. Remove the steering shaft nut. 11. Remove the steering wheel from the steering shaft. 12. Remove the SIR connector from the steering wheel. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Specifications > Page 6839 1. Route the SIR connector through the steering wheel. 2. Align the scribe mark on the steering wheel with the slash mark on the steering shaft. 3. Install the steering wheel. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the steering shaft nut. ^ Tighten the nut to 45 Nm (33 ft. lbs.). 5. Install the Inflatable restraint steering wheel module. 6. Enable the SIR system. 7. Inspect the operation of the following components: ^ The horn ^ The steering wheel ^ The steering wheel controls Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > Customer Interest: > 06-02-32-005 > May > 06 > Steering - Snap/Pop Noise When Turning Steering Wheel Tie Rod Boot: Customer Interest Steering - Snap/Pop Noise When Turning Steering Wheel Bulletin No.: 06-02-32-005 Date: May 03, 2006 TECHNICAL Subject: Snap/Pop Type Noise During Steering Wheel Rotation (Replace Inner Tie Rod Boot) Models Condition Some customers may comment about a snap or pop type noise coming from the front of the vehicle. This noise usually occurs during steering wheel rotation. Cause The cause of this condition may be due to the inner tie rod boot collapsing unevenly, allowing for contact between the inner tie rod and the boot. This condition is sometimes referred to as "snaking." Diagnosis If unsure the noise is coming from the inner tie rod boot(s), have an assistant rotate the steering wheel from lock to lock with the engine off. Place your fingertips on the inner tie rod boot. If the boot is contacting the inner tie rod, that contact will be transmitted to your fingertips. Correction Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > Customer Interest: > 06-02-32-005 > May > 06 > Steering - Snap/Pop Noise When Turning Steering Wheel > Page 6849 Replace the inner tie rod boot. Refer to the Rack and Pinion Boot Replacement procedure in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod Boot: > 06-02-32-009B > Nov > 08 > Steering Noise Diagnostics TSB References Tie Rod Boot: All Technical Service Bulletins Steering - Noise Diagnostics TSB References INFORMATION Bulletin No.: 06-02-32-009B Date: November 19, 2008 Subject: Overview of Steering System Noises Models: 2001-2004 Buick Regal 2001-2005 Buick Century 2005-2007 Buick Allure (Canada Only), LaCrosse 2000-2006 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 1998-2002 Oldsmobile Intrigue 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to remove reference to Corporate Bulletin Number 01-02-32-001 from the table below. Please discard Corporate Bulletin Number 06-02-32-009A (Section 02 - Steering). The purpose of this bulletin is to provide a quick reference for dealers to aid in locating the correct service bulletin for several different steering system noise concerns. Many customer concerns with the steering system involve specific symptoms (noises heard). Once the customer concern has been verified, the table above may help identify the correct bulletin to reference. If other symptoms are present, or if diagnosis indicates another cause not found in any of the three service bulletins, refer to SI to diagnose the repair customer concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod Boot: > 06-02-32-005 > May > 06 > Steering Snap/Pop Noise When Turning Steering Wheel Tie Rod Boot: All Technical Service Bulletins Steering - Snap/Pop Noise When Turning Steering Wheel Bulletin No.: 06-02-32-005 Date: May 03, 2006 TECHNICAL Subject: Snap/Pop Type Noise During Steering Wheel Rotation (Replace Inner Tie Rod Boot) Models Condition Some customers may comment about a snap or pop type noise coming from the front of the vehicle. This noise usually occurs during steering wheel rotation. Cause The cause of this condition may be due to the inner tie rod boot collapsing unevenly, allowing for contact between the inner tie rod and the boot. This condition is sometimes referred to as "snaking." Diagnosis If unsure the noise is coming from the inner tie rod boot(s), have an assistant rotate the steering wheel from lock to lock with the engine off. Place your fingertips on the inner tie rod boot. If the boot is contacting the inner tie rod, that contact will be transmitted to your fingertips. Correction Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod Boot: > 06-02-32-005 > May > 06 > Steering Snap/Pop Noise When Turning Steering Wheel > Page 6859 Replace the inner tie rod boot. Refer to the Rack and Pinion Boot Replacement procedure in SI. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tie Rod Boot: > 06-02-32-009B > Nov > 08 > Steering - Noise Diagnostics TSB References Tie Rod Boot: All Technical Service Bulletins Steering - Noise Diagnostics TSB References INFORMATION Bulletin No.: 06-02-32-009B Date: November 19, 2008 Subject: Overview of Steering System Noises Models: 2001-2004 Buick Regal 2001-2005 Buick Century 2005-2007 Buick Allure (Canada Only), LaCrosse 2000-2006 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 1998-2002 Oldsmobile Intrigue 2004-2007 Pontiac Grand Prix Supercede: This bulletin is being revised to remove reference to Corporate Bulletin Number 01-02-32-001 from the table below. Please discard Corporate Bulletin Number 06-02-32-009A (Section 02 - Steering). The purpose of this bulletin is to provide a quick reference for dealers to aid in locating the correct service bulletin for several different steering system noise concerns. Many customer concerns with the steering system involve specific symptoms (noises heard). Once the customer concern has been verified, the table above may help identify the correct bulletin to reference. If other symptoms are present, or if diagnosis indicates another cause not found in any of the three service bulletins, refer to SI to diagnose the repair customer concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Outer Tie Rod Tie Rod End: Specifications Outer Tie Rod The content of this article reflects the changes called out by TSB 05-02-32-003. Outer Tie Rod End Nut ........................................................................................................................ ......................................... 30 N.m (22 ft.lb.) + 120° Tie Rod End Jam Nut ......................................... ......................................................................................................................................... 70 N.m (52 ft.lb.) Visually inspect to ensure that 2 1/2 - 4 1/2 threads are visible past the nylon washer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Outer Tie Rod > Page 6869 Tie Rod End: Specifications Inner Tie Rod Inner Tie Rod ....................................................................................................................................... ................................................................... 74 ft. lbs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 6870 Tie Rod End: Service and Repair NOTE: The content of this article / image reflects the changes called out by TSB: 05-02-32-003 Rack and Pinion Outer Tie Rod End Replacement ^ Tools Required J 24319-B Universal Steering Linkage Puller Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the prevailing torque nut (2) from the outer tie rod assembly (1). 4. Loosen the jam nut (2) on the inner tie rod assembly (1). Notice: Do not attempt to disconnect a steering linkage joint by driving a wedge between the joint and the attached part. Seal damage may result Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 6871 which will cause premature failure of the joint. 5. Remove the outer tie rod assembly from the steering knuckle using J24319-B. 6. Remove the outer tie rod assembly (3) from the inner tie rod assembly (1). Installation Procedure 1. Install the outer tie rod assembly (3) to the inner tie rod assembly (1). Do NOT tighten the jam nut (2). 2. Install the outer tie rod assembly (2) to the steering knuckle (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Specifications > Page 6872 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the prevailing torque nut (2) to the outer tie rod assembly (1). ^ Tighten the nut to 30 Nm (22 ft. lbs.) + 120° of rotation. NOTE: Visually inspect to ensure that 2 1/2 - 4 1/2 threads are visible past the nylon washer. Tighten the jam nut to 70 Nm (52 ft. lbs.). 4. Install tire and wheel assembly. 5. Lower the vehicle. 6. Perform a front end alignment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection Ball Joint Inspection Step 1-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 6877 Ball Joint: Service and Repair Lower Ball Joint Replacement ^ Tools Required J 41820 Ball Joint/Stud Separator Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Drill a pilot hole through the rivets. 4. Drill the remainder of the rivets. 5. Use a hammer and a chisel in order to remove the remainder of the rivet heads. 6. Remove the cotter pin from the ball stud. 7. Loosen the ball stud nut. 8. Install the J 41820 over the ball stud and lower control arm. 9. Rotate the ball stud nut counterclockwise in order to separate the ball stud from the steering knuckle. 10. Remove the J41820. 11. Remove the ball stud nut. 12. Remove the ball stud from the lower control arm. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Page 6878 1. Install the ball stud to the lower control arm. 2. Install the NEW ball stud bolts facing down, away from the ball stud. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the NEW ball stud nuts. ^ Tighten the NEW ball stud nuts to 68 Nm (50 ft. lbs.). 4. Install the ball stud to the steering knuckle. 5. Install the ball stud castle nut. ^ Tighten the nut to 20 Nm (15 ft. lbs.) plus an additional 120°. 6. Install a new cotter pin and bend the ends. 7. Install the tire and wheels. 8. Lower the vehicle. 9. Check the wheel alignment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Vertical Control Arm Bushing: Service and Repair Vertical Lower Control Arm Bushings Replacement (Vertical) ^ Tools Required ^ J 21474-01 Control Arm Bushing Set J 21474-271/2 Inch Puller Bolt Thrust Bearing - J 21474-2 Bushing Installer Remover - J 21474-4 Nut - J 21474-13 Control Arm Bushing Installer ^ J 23444-A High Pressure Lubricant ^ J 34126 Driven Sprocket Support Bearing Installer ^ J 35379 Front Knuckle Support Removal Procedure 1. Remove the lower control arm. 2. Secure the lower control arm in a vice. 3. Mark the lower control arm along the flat edge of the bushing flange. Important: Apply J 23444-A or equivalent to the threads of J 21474-27. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Vertical > Page 6884 4. Assemble the following bushing removal tools as shown: 4.1. J 21474-27 4.2. J 21474-13 4.3. J 34126 4.4. J 35379 4.5. J 21474-2 4.6. J 21474-4 5. Tighten J21474-4. 6. Disassemble the bushing removal tools. Installation Procedure Important: You MUST install the lower control arm vertical bushing in the same position in order to maintain the original vehicle ride, handling, and road feel. 1. Align the flat edge of the bushing flange to the mark in the control arm (1). Ensure that the flat edge of the bushing flange is 30 degrees (2) from the centerline of the lower control arm. Ensure that the thin slot in the bushing is facing outboard. 2. Insert the bushing into the control arm. Important: Apply J23444-A or equivalent to the threads of J 21474-27. 3. Assemble the following bushing installation tools as shown: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Vertical > Page 6885 3.1. J 21474-27 3.2. J 21474-13 3.3. J 21474-5 3.4. J 21474-4 4. Tighten J 21474-4. 5. Disassemble the bushing installation tools. 6. Install the lower control arm. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Vertical > Page 6886 Control Arm Bushing: Service and Repair Horizontal Lower Control Arm Bushings Replacement (Horizontal) ^ Tools Required J 21474-01 Control Arm Bushing Service Set - J 21474-5Control Arm Bushing Receiver Removal Procedure 1. Remove the lower control arm. 2. Secure the lower control arm in a vise. Important: Use a 1/2 x 20 in standard thread nut with the puller bolt. 3. Assemble the bushing removal tools as indicated: 3.1. The nut (1) 3.2. The J21474-01 washer (2) 3.3. The J21474-01 bearing (3) 3.4. The J21474-5 (4) 3.5. The J21474-01 puller bolt (5) 4. Tighten the puller bolt (5) until the bushing is removed. 5. Disassemble the J21474-01 and J21474-5. Installation Procedure 1. Lubricate the bushing with liquid hand soap or equivalent. Important: Use a 1/2 x 20 in standard thread nut with the puller bolt. 2. Assemble the following bushing installation tools as indicated: 2.1. The nut (1) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component Information > Service and Repair > Vertical > Page 6887 2.2. The J21474-01 washer (2) 2.3. The J21474-01 bearing (3) 2.4. The J 21474-5 (4) 2.5. The J21474-01 puller bolt (5) 3. Tighten the puller bolt (5) until the bushing is installed into the control arm. 4. Disassemble the J21474-01 and J21474-5. 5. Remove the control arm from the vice. 6. Install the lower control arm. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair Cross-Member: Service and Repair Brace Replacement - Cross Vehicle Removal Procedure 1. Open the hood. 2. Remove the nuts from the cross vehicle brace. 3. Remove the cross vehicle brace from the vehicle. Important: Be careful, the stud plates may fall out and possibly get caught under the vehicle during the removal. 4. Remove the stud plates push on nuts from the studs. 5. Remove the stud plates from the vehicle. Installation Procedure Important: The stud plates will require an assistant to hold the stud plates during the installation of the push on nuts. 1. Install the stud plates to the vehicle. 2. Install the stud plates push on nuts to the studs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Service and Repair > Page 6891 3. Install the cross vehicle brace to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the nuts to the cross vehicle brace. Tighten the cross vehicle brace nuts to 18 N.m (13 lb ft). 5. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Recalls for Front Steering Knuckle: > NHTSA04V287000 > Jun > 04 > Recall 04V287000: Caliper Mounting Bolt Torque Front Steering Knuckle: Recalls Recall 04V287000: Caliper Mounting Bolt Torque DEFECT: Certain passenger vehicles were produced with lower than specified torque on both front brake calipers to steering knuckle attachment bolts. With improper torque, the clamp load at the joint may not be adequate to prevent movement between the caliper bracket and knuckle. Depending on whether one or both bolts backs out or fractures, the result can be locking of the affected wheel during braking and an abrupt steering input in the direction of the locked wheel, reduced braking and noise from the affected wheel, or severing of a brake hose, increased brake pedal travel, and reduced steering control. Reduced braking or steering control could cause a crash. REMEDY: Dealers are to tighten both bolts to the specified torque. The manufacturer has reported that owner notification began on July 6, 2004. Owners may contact Chevrolet at 1-800-630-2438 or Pontiac at 1-800-620-7668. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Front Steering Knuckle: > NHTSA04V287000 > Jun > 04 > Recall 04V287000: Caliper Mounting Bolt Torque Front Steering Knuckle: All Technical Service Bulletins Recall 04V287000: Caliper Mounting Bolt Torque DEFECT: Certain passenger vehicles were produced with lower than specified torque on both front brake calipers to steering knuckle attachment bolts. With improper torque, the clamp load at the joint may not be adequate to prevent movement between the caliper bracket and knuckle. Depending on whether one or both bolts backs out or fractures, the result can be locking of the affected wheel during braking and an abrupt steering input in the direction of the locked wheel, reduced braking and noise from the affected wheel, or severing of a brake hose, increased brake pedal travel, and reduced steering control. Reduced braking or steering control could cause a crash. REMEDY: Dealers are to tighten both bolts to the specified torque. The manufacturer has reported that owner notification began on July 6, 2004. Owners may contact Chevrolet at 1-800-630-2438 or Pontiac at 1-800-620-7668. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 6905 Front Steering Knuckle: Service and Repair Steering Knuckle Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the bearing/hub assembly. 3. Remove the front lower control arm ball stud. 4. Remove the outer tie rod end from the steering knuckle. 5. Scribe the strut to the knuckle. 6. Remove the bolts and nuts attaching the strut to the knuckle. 7. Remove the knuckle from the vehicle. Installation Procedure 1. Install the knuckle to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Technical Service Bulletins > Page 6906 2. Install the bolts and nuts attaching the strut to the knuckle. ^ Tighten the strut to knuckle bolts to 120 Nm (89 ft. lbs.). 3. Install the outer tie rod to the steering knuckle. 4. Connect the front lower control arm ball stud to the knuckle. 5. Install the front wheel drive shaft bearing. 6. Lower the vehicle. 7. Inspect the front wheel alignment and adjust if necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair Rear Knuckle: Service and Repair Knuckle Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Scribe the strut to the knuckle. 4. Remove the bearing/hub assembly. 5. Remove the rear wheel spindle rods from the knuckle. 6. Remove the trailing arm (2) from the knuckle (3). 7. Remove the rear strut to knuckle bolts (2) and the nuts (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 6910 8. Remove the knuckle (5) from the vehicle. Installation Procedure 1. Install the knuckle to the vehicle. 2. Hand start the strut to knuckle bolts (2) and nuts (1). Do not tighten the nuts at this time. 3. Connect the rear suspension trailing arm (2) to the knuckle (3). 4. Connect the rear wheel spindle rods to the knuckle. 5. Install the bearing/hub assembly. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Service and Repair > Page 6911 6. Tighten the strut to knuckle bolts (2) and nuts (1). ^ Tighten bolts to 120 Nm (89 ft. lbs.). 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Inspect the rear wheel alignment, adjust if necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair Spindle: Service and Repair Spindle Rod Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. Important: Use a transmission jack or suitable hoist stands to prop the rear suspension support. 3. Lower the rear suspension support to gain clearance to the spindle rod to knuckle bolt. 4. Remove the bolt (1) and nut from the spindle rod and the rear suspension support. 5. Remove the spindle rod to knuckle bolt (4) and nut. 6. Push the spindle rod to knuckle bolt (4) forward enough to provide clearance for the spindle rod (5) removal. 7. Remove the spindle rod (5) from the vehicle. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Service and Repair > Page 6915 1. Install the spindle rod (5) to the vehicle. 2. Install the spindle rod (5) to the knuckle (8). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the spindle rod to knuckle bolt (4) and nut. ^ Tighten the nut to 150 Nm (110 ft. lbs.). 4. Install the spindle rod to the rear suspension support. 5. Install the bolt (1) and nut to the rear suspension support. ^ Tighten the bolt to 140 Nm (103 ft. lbs.). 6. Install the rear suspension support. 7. Install the tire and wheel assembly. 8. Lower the vehicle. 9. Adjust the wheel toe angle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front Suspension Stabilizer Bushing: Service and Repair Front Suspension Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the left and right side stabilizer shaft insulator bracket bolts. 3. Remove the left and right side stabilizer shaft insulator brackets. 4. Remove the left and right side stabilizer shaft insulators (1) from the stabilizer shaft (2). Installation Procedure 1. Install the left and right side stabilizer shaft insulators (1) to the stabilizer shaft (2). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front Suspension > Page 6921 2. Install the left and right side stabilizer shaft insulator brackets. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the left and right side stabilizer shaft insulator bracket bolts. ^ Tighten the stabilizer shaft insulator bracket bolts to 30 Nm (22 in. lbs.). 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing > Component Information > Service and Repair > Front Suspension > Page 6922 Stabilizer Bushing: Service and Repair Rear Suspension Stabilizer Shaft Insulator Replacement Removal Procedure 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the bolt from the stabilizer shaft insulator bracket (3). 3. Remove the stabilizer shaft insulator bracket. 4. Remove the stabilizer shaft insulator (2) from the stabilizer shaft. Installation Procedure 1. Install the stabilizer shaft insulator (2) to the stabilizer shaft. 2. Install the stabilizer shaft insulator bracket (3). Notice: Refer to Fastener Notice in Service Precautions. 3. Install the stabilizer shaft bracket nuts. ^ Tighten the bolts to 48 Nm (35 ft. lbs.). 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension Stabilizer Link: Service and Repair Front Suspension Stabilizer Shaft Link Replacement Removal Procedure 1. Raise the vehicle and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the stabilizer shaft link bolt and nut. 4. Remove the stabilizer shaft link from the vehicle. Installation Procedure 1. Install the stabilizer link into the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the stabilizer shaft link bolt and nut. ^ Tighten the stabilizer shaft link nut to 23 Nm (17 ft. lbs.). 3. Install the tire and wheel assembly. 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 6927 Stabilizer Link: Service and Repair Rear Suspension Stabilizer Shaft Link Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the stabilizer shaft link nut from the stabilizer shaft link (1) and the stabilizer shaft (2). 3. Remove the stabilizer shaft link nut from the stabilizer shaft link (1) and the strut. 4. Remove the stabilizer shaft link (1) from the vehicle. Installation Procedure 1. Install the stabilizer shaft link (1) to the vehicle. 2. Connect the stabilizer shaft link (1) to the stabilizer shaft (2). Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Service and Repair > Front Suspension > Page 6928 3. Install the stabilizer shaft link nut to the stabilizer shaft link (1) and the stabilizer shaft (2). ^ Tighten the nut to 52 Nm (38 ft. lbs.). 4. Connect the stabilizer shaft link (1) to the strut. 5. Install the stabilizer shaft link nut to the stabilizer shaft link (1) and the strut. ^ Tighten the nut to 52 Nm (38 ft. lbs.). 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair Front Subframe: Service and Repair Frame Replacement Tools Required J 39580 Universal Engine Support Table Removal Procedure 1. Install the engine support fixture. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the front tires and wheels. 4. Remove the lower radiator air deflector. 5. Remove the positive battery cable retainers. Position the positive battery cable aside. 6. Disconnect the power steering cooler pipe from the frame. 7. Secure the power steering cooler to the exhaust pipe. 8. Remove the stabilizer shaft links. Rotate the stabilizer shaft up to gain access to the mounting bolts for the power steering gear. 9. Remove the mounting bolts for the power steering gear. 10. Secure the power steering gear. 11. Remove the nuts which secure the engine mount to the frame. 12. Remove the nuts which secure the transaxle mount to the frame. 13. Disconnect both front wheel speed sensor connectors (1), if equipped. 14. Remove both front wheel speed harness retainers (2) from the frame and the lower control arms, if equipped. 15. Separate both of the lower ball joints from the steering knuckle. Refer to Lower Ball Joint Replacement in Front Suspension. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 6933 16. Lower the vehicle until the frame contacts J 39580. 17. Remove the bolts which secure the front frame to the body. 18. Remove the bolts which secure the rear frame to the body. 19. Raise the vehicle in order to separate the frame from the body. 20. If you are replacing the frame, remove the following components: * Both of the lower control arms. Refer to Lower Control Arm Replacement in Front Suspension. * The stabilizer shaft. Refer to Stabilizer Shaft Replacement in Front Suspension. * The spacers, the upper insulator, the lower insulator, and the retainers. Refer to Frame Cushion or Insulator Replacement - Front and to Frame Cushion or Insulator Replacement - Rear. Installation Procedure 1. If you are replacing the frame, install the following components: * Both of the lower control arms. Refer to Lower Control Arm Replacement in Front Suspension. * The stabilizer shaft. Refer to Stabilizer Shaft Replacement in Front Suspension. * The spacers, the upper insulator, the lower insulator, and the retainers. Refer to Frame Cushion or Insulator Replacement - Front and to Frame Cushion or Insulator Replacement - Rear. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 6934 2. Position the engine support table with the frame under the vehicle. 3. Lower the vehicle to the frame. 4. Loosely install the bolts to secure the rear frame to the body. 5. Loosely install the bolts to secure the front and rear frame to the body. Notice: Refer to Fastener Notice in Service Precautions. 6. Align the frame to the body by inserting two 19X203 mm (0.74X8.0 in) pins in the alignment holes on the right side of the frame. * Tighten the new front frame bolts to 160 N.m (118 lb ft). * Tighten the new rear frame bolts to 165 N.m (122 lb ft). 7. Connect both the lower ball joints to the steering knuckle. 8. Install the nuts which secure the engine mount to the frame. * Engine Mount Replacement in Engine - 3.4L * Engine Mount and Bracket Replacement in Engine - 3.8L 9. Install the nuts which secure the transaxle mount to the frame. 10. Remove the power steering gear from the exhaust pipe. Position to the frame. 11. Install the steering gear mounting bolts. 12. Install the stabilizer shaft links. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Subframe > Front Subframe > System Information > Service and Repair > Page 6935 13. Connect both front wheel speed sensor connectors (1), if equipped. 14. Install both front wheel speed harness retainers (2) to the frame and to the lower control arm, if equipped. 15. Install the positive battery cable. 16. Install the power steering cooler pipe. 17. Install the radiator lower air deflector. 18. Install the front tires and wheels. 19. Lower the vehicle. 20. Remove the engine support fixture. 21. Inspect the front wheel alignment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information Suspension Strut / Shock Absorber: Technical Service Bulletins Suspension - Shock Absorber/Strut Leakage Information INFORMATION Bulletin No.: 05-03-08-002C Date: October 16, 2009 Subject: Information on Replacement of Shock Absorbers and Struts Due to Fluid Leaks Models: 2010 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add the 2010 model year and Inspection Procedures. Please discard Corporate Bulletin Number 05-03-08-002B (Section 03 - Suspension). This bulletin is intended to help identify the severity of shock absorber and strut fluid seepage. Improper diagnosis may lead to components being replaced that are within the manufacturer's specification. Shock absorbers and strut assemblies are fluid-filled components and will normally exhibit some seepage. Seepage is defined as oil film or dust accumulation on the exterior of the shock housing. Shock absorbers and struts are not to be replaced under warranty for seepage. Use the following information to determine if the condition is normal acceptable seepage or a defective component. Important Electronically controlled shock absorbers (MR) may have a tendency to attract dust to this oil film. Often this film and dust can be wiped off and will not return until similar mileage is accumulated again. Inspection Procedure Note The shock absorber or strut assembly DOES NOT have to be removed from the vehicle to perform the following inspection procedure. Use the following descriptions and graphics to determine the serviceability of the component. Shock Absorbers Do Not Replace shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom or top of the shock absorber and not originating from the shaft seal (the upper part of the lower shock tube). 2. Light film/residue on approximately 1/3 (a) or less of the lower shock tube (A) and originating from the shaft seal. Replace shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme wet film of oil covering more than 1/3 (b) of the lower shock tube and originating from the shaft seal. Coil-over Shock Absorber Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Suspension - Shock Absorber/Strut Leakage Information > Page 6940 Do Not Replace coil-over shock absorbers displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the lower shock absorber tube or the coil-over shock absorber components and not originating from the shaft seal (located at the top of the coil-over shock tube). 2. Light film/residue on the shock absorber tube, but not on the spring seat and originating from the shaft seal. Replace coil-over shock absorbers displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the lower shock tube and originating from the shaft seal. 4. An extreme, wet film of oil covering the shock absorber tube and pooling in the spring seat and originating from the shaft seal. Struts Do Not Replace Struts displaying condition 1 or 2 levels of seepage. 1. Oil or fluid residue only on the bottom of the strut tube or on other strut components and not originating from the shaft seal. 2. Light film/residue on the strut tube, but not on the spring seat and originating from the shaft seal. Replace Struts displaying conditions 3 and 4 levels of leaks. 3. Oil drip or trail down the strut tube and originating from the shaft seal (located at the top of the strut tube). 4. Extreme wet film of oil covering the strut tube and pooling in the spring seat and originating from the shaft seal. Correction Use the information published in SI for diagnosis and repair. Use the applicable published labor operation. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front Suspension Strut / Shock Absorber: Service and Repair Front Strut Assembly Replacement Strut Assembly Replacement Removal Procedure 1. Remove the strut upper nuts. Important: Lift the vehicle using ONLY a frame-contact vehicle lift. Do NOT lift the vehicle using a suspension-contact vehicle lift. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel. 4. Scribe the strut to the knuckle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 6943 5. Remove the strut lower bolts and nuts. 6. Remove the strut. Installation Procedure 1. Install the strut. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the strut upper nuts. ^ Tighten the strut upper nuts to 33 Nm (24 ft. lbs.). 3. Install the strut lower bolts and nuts. Important: This is a prevailing torque type fastener. This fastener may be reused ONLY if: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 6944 ^ The fastener and its counterpart are clean and free from rust. ^ The fastener develops 3 Nm (27 in. lbs.) of torque/drag against its counterpart prior to the fastener seating. If the fastener does not meet these criteria, REPLACE the fastener. 4. Align the strut to the mark on the knuckle. ^ Tighten the strut lower nuts to 122 Nm (90 ft. lbs.). 5. Install the tire and wheel. 6. Lower the vehicle. 7. Align the front wheels. Suspension Strut Disposal Suspension Strut Disposal Caution: Use the proper eye protection when drilling to prevent metal chips from causing physical injury. 1. Clamp the strut in a vise horizontally with the rod (1) completely extended. 2. Drill a hole in the strut at the center of the end cap (3) using a 5 mm (3/16 in.) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the strut. Use shop towels in order to contain the escaping oil. 3. Remove the strut from the vise. 4. Hold the strut over a drain pan vertically with the hole down. 5. Move the rod (1) in and out of the tube (2) to completely drain the oil from the strut. Strut, Strut Component and/or Spring Replacement Strut, Strut Component and/or Spring Replacement ^ Tools Required J 42991 Strut Rod Nut Socket - J 45400 Strut Spring Compressor Disassembly Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 6945 1. Remove the strut from the vehicle. 2. Install the strut (2) in the J45400 (1). Important: The spring is compressed when the strut moves freely. 3. Turn the spring compressor forcing screw (1) until the coil spring (2) is compressed. 4. Use a 45 TORCH socket in order to hold the strut shaft. Remove the upper strut mount nut by turning with J42991. 5. Remove the strut from the J 45400. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 6946 6. Loosen the compressor forcing screw (1) until the upper strut mount and coil spring (2) may be removed. 7. Remove the upper strut mount and the coil spring from the J 45400. Assembly Procedure 1. Install the coil spring and upper strut mount to the J 45400. 2. Turn the spring compressor forcing screw (1) until the coil spring is compressed. 3. Install the strut to the coil spring and upper strut mount. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the strut retaining nut. Using the J 42991 and a 45 TORX socket, install the strut mount nut. ^ Tighten the strut mount nut to 85 Nm (63 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 6947 5. Remove the strut from the J 45400. 6. Install the strut to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 6948 Suspension Strut / Shock Absorber: Service and Repair Rear Strut Assembly Strut Assembly Replacement Strut Assembly Replacement Removal Procedure Notice: Care should be taken to avoid chipping or scratching the coating when handling the suspension coil spring. Damage to the coating can cause premature failure. 1. Remove the strut-to-body mount nuts (1). 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the tire and wheel assembly. 4. Remove the stabilizer shaft link from the strut. 5. Remove the bolt (2) from the brake hose bracket (3) and the strut assembly. 6. Scribe the strut to the knuckle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 6949 Notice: The knuckle must be retained after the strut-to-knuckle bolts have been removed. Failure to observe this may cause ball joint and/or wheel drive shaft damage. 7. Remove the strut to knuckle bolts. 8. Remove the strut from the vehicle. Installation Procedure Notice: Care should be taken to avoid chipping or scratching the coating when handling the suspension coil spring. Damage to the coating can cause premature failure. 1. Install the strut into place. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the strut to knuckle bolts. ^ Tighten the strut to knuckle bolts and nuts to 120 Nm (89 ft. lbs.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 6950 3. Install the bolt (2) to the brake hose bracket (3) and the strut assembly. ^ Tighten the bolt to 27 Nm (20 ft. lbs.). 4. Connect the stabilizer shaft link to the strut. 5. Install the tire and wheel. 6. Install strut to body mount nuts (1). ^ Tighten the strut to body mount nuts to 45 Nm (33 ft. lbs.). 7. Lower the vehicle. 8. Adjust the rear wheel alignment. Suspension Strut Disposal Suspension Strut Disposal Caution: Use the proper eye protection when drilling to prevent metal chips from causing physical injury. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 6951 1. Clamp the strut in a vise horizontally with the rod (1) completely extended. 2. Drill a hole in the strut at the center of the end cap (3) using a 5 mm (3/16 in.) drill bit. Gas or a gas/oil mixture will exhaust when the drill bit penetrates the strut. Use shop towels in order to contain the escaping oil. 3. Remove the strut from the vise. 4. Hold the strut over a drain pan vertically with the hole down. 5. Move the rod (1) in and out of the tube (2) to completely drain the oil from the strut. Strut, Strut Component and/or Spring Replacement Strut, Strut Component and/or Spring Replacement ^ Tools Required J 42991 Strut Rod Nut Socket - J 45400 Strut Spring Compressor Disassembly Procedure 1. Remove the strut from the vehicle. 2. Install the strut (2) in the J 45400 (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 6952 Important: The spring is compressed when the strut moves freely. 3. Turn the spring compressor forcing screw (1) until the coil spring (2) is compressed. 4. Use a 45 TORX socket in order to hold the strut shaft. Remove the upper strut mount nut by turning with J 42991. 5. Remove the strut from the J 45400. 6. Loosen the compressor forcing screw (1) until the upper strut mount and coil spring (2) may be removed. 7. Remove the upper strut mount and the coil spring from the J 45400. Assembly Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Front > Page 6953 1. Install the coil spring and upper strut mount to the J 45400. 2. Turn the spring compressor forcing screw (1) until the coil spring is compressed. 3. Install the strut to the coil spring and upper strut mount. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the strut retaining nut. Using the J42991 and a 45 TORCH socket, install the strut mount nut. ^ Tighten the strut mount nut to 85 Nm (63 ft. lbs.). 5. Remove the strut from the J 45400. 6. Install the strut to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information > Service and Repair Trailing Arm: Service and Repair Trailing Arm Replacement Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the bolt (6) and nut (2) from the trailing arm (3) and the knuckle (8). 3. Remove the nut (4) and bolt (7) from the trailing arm (3) and the trailing arm bracket. 4. Remove the trailing arm (3) from the vehicle. Installation Procedure 1. Install the trailing arm (3) to the trailing arm bracket. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolt (7) and nut (4) to the trailing arm (3) and the trailing arm bracket. ^ Tighten the bolt and nut to 105 Nm (77 ft. lbs.). 3. Install the trailing arm (3) to the knuckle (8). 4. Install the bolt (6) and nut (2) to the trailing arm (3) and the knuckle (8). ^ Tighten the nut to 70 Nm + 65° (52 ft. lbs. + 65°). 5. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Front Wheel Bearing/Hub Bolts ............................................................................................................................................................. 130 Nm (96 ft. lbs.) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 6961 Wheel Bearing: Fluid Type Specifications FRONT WHEEL BEARINGS Wheel bearing lubricant meeting requirements of NLGI # 2, Category GC or GC-LB (GM Part No. U.S. 1051344, in Canada 993037). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 6962 Wheel Bearings Diagnosis Step 1-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Bearing/Hub Replacement - Front ^ Tools Required J 42129 Wheel Hub Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Disconnect the wheel speed sensor electrical connector (2), if equipped. 4. Remove the wheel speed sensor electrical connector from the bracket, if equipped. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6965 5. Remove the front wheel drive shaft nut (2). Insert a drift or flat bladed tool (1) into the caliper and rotor to prevent from turning. 6. Remove the brake rotor. 7. Use 3 wheel nuts in order to attach the J 42129 to the wheel bearing/hub. 8. Use the J 42129 in order to push the wheel drive shaft out of the wheel bearing/hub. 9. Remove and DISCARD the wheel bearing/hub bolts. Remove the J 42129 from the hub. Important: Ensure that the wheel drive shaft outer seal/boot is not damaged. 10. Remove the wheel bearing/hub and splash shield-noting the position of the shield for reinstallation. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6966 1. Install the wheel bearing/hub with the splash shield as noted during removal. Caution: These fasteners MUST be replaced with new fasteners anytime they become loose or are removed. Failure to replace these fasteners after they become loose or are removed may cause loss of vehicle control and personal injury. Notice: Refer to Fastener Notice in Service Precautions. 2. Install NEW wheel bearing/hub bolts. ^ Tighten the NEW wheel bearing/hub bolts to 130 Nm (96 ft. lbs.). 3. Install the brake rotor and caliper. 4. Install the front wheel drive shaft nut. Insert a drift on a flat bladed tool into caliper and rotor to prevent the rotor from turning. ^ Tighten the front wheel drive shaft nut to 160 Nm (118 ft. lbs.). Important: Ensure that the connector clip engages the bracket properly. 5. Install the wheel speed sensor electrical connector to the bracket, if equipped. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6967 6. Connect the wheel speed sensor electrical connector (2), if equipped. 7. Install the tire and wheel. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6968 Wheel Bearing: Service and Repair Rear Wheel Bearing/Hub Replacement - Rear Removal Procedure Important: The wheel bearing in the rear wheel hub is integrated into one unit. The hub is non-serviceable. If the hub and/or bearing is damaged, replace the complete hub and bearing assembly. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tires and wheels. 3. Remove the brake rotor. 4. Remove the ABS electrical connector from the wheel speed sensor (1), if equipped. 5. Remove the park brake cable from the park brake actuator. 6. Remove the mounting bolts from the rear bearing/hub. 7. Remove the wheel bearing/hub and park brake assembly from the knuckle. 8. Remove the park brake actuator from the rear wheel bearing/hub. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6969 1. Install the park brake actuator to the rear wheel bearing/hub. 2. install the wheel bearing/hub and park brake assembly to the knuckle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the wheel bearing/hub-to-knuckle bolts. ^ Tighten the bolts to 75 Nm (55 ft. lbs.). 4. Install the park brake cable to the park brake actuator. 5. Install the ABS electrical connector to the wheel speed sensor (1), if equipped. 6. Install the brake rotor. 7. Install the tires and wheels. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Drive Shaft Nut ........................................................................................................................... ................................................... 160 N.m (118 lb ft) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Relays and Modules - Wheels and Tires > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Sensors and Switches - Wheels and Tires > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 6989 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System - TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 7003 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tires: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 7008 Tires: Technical Service Bulletins Wheels/Tires - Use of Nitrogen Gas in Tires INFORMATION Bulletin No.: 05-03-10-020C Date: April 27, 2010 Subject: Use of Nitrogen Gas in Tires Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-03-10-020B (Section 03 - Suspension). GM's Position on the Use of Nitrogen Gas in Tires General Motors does not oppose the use of purified nitrogen as an inflation gas for tires. We expect the theoretical benefits to be reduced in practical use due to the lack of an existing infrastructure to continuously facilitate inflating tires with nearly pure nitrogen. Even occasional inflation with compressed atmospheric air will negate many of the theoretical benefits. Given those theoretical benefits, practical limitations, and the robust design of GM original equipment TPC tires, the realized benefits to our customer of inflating their tires with purified nitrogen are expected to be minimal. The Promise of Nitrogen: Under Controlled Conditions Recently, nitrogen gas (for use in inflating tires) has become available to the general consumer through some retailers. The use of nitrogen gas to inflate tires is a technology used in automobile racing. The following benefits under controlled conditions are attributed to nitrogen gas and its unique properties: - A reduction in the expected loss of Tire Pressure over time. - A reduction in the variance of Tire Pressures with temperature changes due to reduction of water vapor concentration. - A reduction of long term rubber degradation due to a decrease in oxygen concentrations. Important These are obtainable performance improvements when relatively pure nitrogen gas is used to inflate tires under controlled conditions. The Promise of Nitrogen: Real World Use Nitrogen inflation can provide some benefit by reducing gas migration (pressure loss) at the molecular level through the tire structure. NHTSA (National Highway Traffic Safety Administration) has stated that the inflation pressure loss of tires can be up to 5% a month. Nitrogen molecules are larger than oxygen molecules and, therefore, are less prone to "seeping" through the tire casing. The actual obtainable benefits of nitrogen vary, based on the physical construction and the materials used in the manufacturing of the tire being inflated. Another potential benefit of nitrogen is the reduced oxidation of tire components. Research has demonstrated that oxygen consumed in the oxidation process of the tire primarily comes from the inflation media. Therefore, it is reasonable to assume that oxidation of tire components can be reduced if the tire is inflated with pure nitrogen. However, only very small amounts of oxygen are required to begin the normal oxidation process. Even slight contamination of the tire inflation gas with compressed atmospheric air during normal inflation pressure maintenance, may negate the benefits of using nitrogen. GM Tire Quality, Technology and Focus of Importance Since 1972, General Motors has designed tires under the TPC (Tire Performance Criteria) specification system, which includes specific requirements that ensure robust tire performance under normal usage. General Motors works with tire suppliers to design and manufacture original equipment tires for GM vehicles. The GM TPC addresses required performance with respect to both inflation pressure retention, and endurance properties for original equipment tires. The inflation pressure retention requirements address availability of oxygen and oxidation concerns, while endurance requirements ensure the mechanical structure of the tire has sufficient strength. This combination has provided our customers with tires that maintain their structural integrity throughout their useful treadlife under normal operating conditions. Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Maintaining the correct inflation pressure allows the tire to perform as intended by the vehicle manufacturer in many areas, including comfort, fuel economy, stopping distance, cornering, traction, treadwear, and noise. Since the load carrying capability of a tire is related to inflation pressure, proper inflation pressure maintenance is necessary for the tire to support the load imposed by the vehicle without excessive structural Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 7009 degradation. Important Regardless of the inflation media for tires (atmospheric air or nitrogen), inflation pressure maintenance of tires is critical for overall tire, and ultimately, vehicle performance. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 7010 Tires: Technical Service Bulletins Tires/Wheels - Tire Puncture Repair Procedures INFORMATION Bulletin No.: 04-03-10-001F Date: April 27, 2010 Subject: Tire Puncture Repair Procedures For All Cars and Light Duty Trucks Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-001E (Section 03 - Suspension). This bulletin covers puncture repair procedures for passenger car and light duty truck radial tires in the tread area only. The tire manufacturer must be contacted for its individual repair policy and whether or not the speed rating is retained after repair. Caution - Tire changing can be dangerous and should be done by trained professionals using proper tools and procedures. Always read and understand any manufacturer's warnings contained in their customers literature or molded into the tire sidewall. - Serious eye and ear injury may result from not wearing adequate eye and ear protection while repairing tires. - NEVER inflate beyond 275 kPa (40 pounds) pressure to seat beads. Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. - NEVER stand, lean or reach over the assembly during inflation. Repairable area on a radial tire. Important - NEVER repair tires worn to the tread indicators 1.59 mm (2/32") remaining depth). - NEVER repair tires with a tread puncture larger than 6.35 mm (1/4"). - NEVER substitute an inner tube for a permissible or non-permissible repair. - NEVER perform an outside-in tire repair (plug only, on the wheel). - Every tire must be removed from the wheel for proper inspection and repair. - Regardless of the type of repair used, the repair must seal the inner liner and fill the injury. - Consult with repair material supplier/manufacturer for repair unit application procedures and repair tools/repair material recommendations. Three basic steps for tire puncture repair: 1. Remove the tire from the wheel for inspection and repair. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 7011 2. Fill the injury (puncture) to keep moisture out. 3. Seal the inner liner with a repair unit to prevent air loss. External Inspection 1. Prior to demounting, inspect the tire surface, the valve and the wheel for the source of the leak by using a water and soap solution. Mark the injured area and totally deflate the tire by removing the valve core. 2. Demount the tire from the wheel and place the tire on a well-lighted spreader. Internal Inspection 1. Spread the beads and mark the puncture with a tire crayon. 2. Inspect the inner tire for any signs of internal damage. 3. Remove the puncturing object, noting the direction of the penetration. 4. Probe the injury with a blunt awl in order to determine the extent and direction of the injury. 5. Remove any loose foreign material from the injury. 6. Punctures exceeding 6.35 mm (1/4") should not be repaired. Cleaning 1. Clean the area around the puncture thoroughly with a proper liner cleaner, clean cloth and a scraper. This step serves to remove dirt and mold lubricants to insure proper adhesion and non-contamination of the buffing tool. 2. Refer to information on the product or manufacturer's Material Safety Data Sheet and follow guidelines for handling and disposal. Clean the Injury Channel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 7012 1. Use a proper hand reamer, carbide cutter or drill bit to ream the puncture channel from the inside of the tire in order to clean the injury. 2. Remove steel wires protruding above the liner surface to prevent damage to the repair unit. 3. Consult your repair material supplier for recommended reaming tool(s). Fill the Injury 1. It is necessary to fill the injury channel to provide back up for the repair unit and to prevent moisture from entering the tire fabric and steel wires. 2. (For combination repair/plug units skip this step.) Cement the injured channel and fill the injury from the inside of the tire with the repair plug per repair material manufacturer's recommendations. Without stretching the plug, cut the plug off just above the inside tire surface. 3. Consult your repair material supplier for proper repair material selection. Repair Unit Selection Important Do not install the repair unit in this step. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 7013 1. Center the repair unit over the injury as a reference and outline an area larger than the unit so that buffing will not remove the crayon marks. 2. Remove the repair unit. 3. DO NOT overlap previous or multiple repair units. 4. Consult your repair material supplier for proper repair unit selection. Buffing 1. To prevent contamination and preserve the outline, buff within the marked area thoroughly and evenly with a low speed buffing tool using a fine wire brush or gritted rasp. 2. Buff to a smooth velvet surface (RMA #1 or #2 buffed texture). 3. Use caution not to gouge the inner liner or expose casing fabric. 4. Remove any buffing dust with a vacuum cleaner. 5. Consult your repair material supplier for a proper buffing tool. Cementing Apply chemical cement according to the repair material manufacturer's procedures. Repair Unit Application Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 7014 1. The tire must be in the relaxed position when the repair unit is installed (Do not spread the beads excessively). Two-Piece Plug and Repair Units 1. If applicable, install the repair unit so that the alignment is correct. 2. Center the repair unit over the injury and stitch down thoroughly with the stitching tool, working from the center out. 3. Being careful not to stretch the plug material, cut the plug flush with the outer tread. Combination Repair/Plug Units 1. Pull the plug through the injury until the repair just reaches the liner. Stitch down thoroughly. 2. Follow the repair material manufacturer's recommendations for further installation instructions. 2. Consult your repair material supplier for the proper stitching tool. Safety Cage Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 7015 Some run flat tires, such as the Goodyear Extended Mobility Tire (EMT) used on the Corvette, may require more than 275 kPa (40 psi) to seat the bead. In such a case, a tire safety cage must be used. Consult the tire manufacturer for its individual repair policy. Final Inspection 1. After remounting and inflating the tire, check both beads, the repair and the valve with a water and soap solution in order to detect leaks. 2. If the tire continues to lose air, the tire must be demounted and reinspected. 3. Balance the tire and wheel assembly. Refer to Tire and Wheel Assembly Balancing - OFF Vehicle. For additional tire puncture repair information, contact: Rubber Manufacturers Association (RMA) Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 7016 Tires: Technical Service Bulletins Tires - Correct Inflation Pressure Information INFORMATION Bulletin No.: 00-00-90-002J Date: January 28, 2009 Subject: Information on Proper Tire Pressure Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3, H3T 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years and clarify additional information. Please discard Corporate Bulletin Number 00-00-90-002I (Section 00 - General Information). Important: ^ Adjustment of tire pressure for a customer with a Low Tire Pressure Monitor (TPM) light on and no codes in the TPM system is NOT a warrantable repair. Claims to simply adjust the tire pressure will be rejected. ^ ALL tires (including the spare tire) MUST be set to the recommended inflation pressure stated on the vehicle's tire placard (on driver's door) during the PRE-DELIVERY INSPECTION (PDI). Recommended inflation pressure is not the pressure printed on tire sidewall. ^ Tires may be over-inflated from the assembly plant due to the mounting process. ^ Generally a 5.6°C (10°F) temperature change will result in (is equivalent to) a 6.9 kPa (1 psi) tire pressure change. ^ 2008-2009 HUMMER H2 Only - The H2 comes standard with Light Truck "D" Load Range tires with a recommended cold inflation pressure of 289 kPa (42 psi). These tires will alert the driver to a low pressure situation at roughly 262 kPa (38 psi) due to a requirement in FMVSS 138 which specifies a Minimum Activation Pressure for each tire type. This creates a relatively narrow window of "usable" pressure values and the warning will be more sensitive to outside temperature changes during the colder months. As with other cold temperature/tire pressure issues, there is nothing wrong with the system itself. If a vehicle is brought in with this concern, check for tire damage and set all tires to the Recommended Cold Inflation Pressure shown on the vehicle placard. Accurate tire pressures ensure the safe handling and appropriate ride characteristics of GM cars and trucks. It is critical that the tire pressure be adjusted to the specifications on the vehicle¡C■s tire placard during PDI. Ride, handling and road noise concerns may be caused by improperly adjusted tire pressure. The first step in the diagnosis of these concerns is to verify that the tires are inflated to the correct pressures. The recommended tire inflation pressure is listed on the vehicle¡C■s tire placard. The tire placard is located on the driver¡C■s side front or rear door edge, center pillar, or the rear compartment lid. Tip ^ Generally a 5.6°C (10°F) temperature increase will result in (is equivalent to) a 6.9 kPa (1 psi) tire pressure increase. ^ The definition of a "cold" tire is one that has been sitting for at least 3 hours, or driven no more than 1.6 km (1 mi). ^ On extremely cold days, if the vehicle has been indoors, it may be necessary to compensate for the low external temperature by adding additional air to the tire during PDI. ^ During cold weather, the Tire Pressure Monitor (TPM) indicator light (a yellow horseshoe with an exclamation point) may illuminate. If this indicator turns off after the tires warm up (reach operating temperature), the tire pressure should be reset to placard pressure at the cold temperature. ^ The TPM system will work correctly with nitrogen in tires. ^ The TPM system is compatible with the GM Vehicle Care Tire Sealant but may not be with other commercially available sealants. Important: ^ Do not use the tire pressure indicated on the tire itself as a guide. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 7017 ^ Always inspect and adjust the pressure when the tires are cold. ^ Vehicles that have different pressures for the front and the rear need to be adjusted after tire rotation. Improper tire inflation may result in any or all of the following conditions: ^ Premature tire wear ^ Harsh ride ^ Excessive road noise ^ Poor handling ^ Reduced fuel economy ^ Low Tire Pressure Monitor (TPM) Light ON ^ Low Tire Pressure Message on the Drivers Information Center (DIC) Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Page 7018 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Removal and Installation Tires: Service and Repair Tire and Wheel Removal and Installation Tire and Wheel Removal and Installation ^ Tools Required J 39544-KIT Complete Torque Socket Set Removal Procedure Caution: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident Notice: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. Notice: Removing wheels can be difficult because of foreign material or a tight fit between the wheel center hole and the hub or rotor. Excessive force, such as hammering on the wheel or tire, can cause damage. Slightly tapping the tire side wall with a rubber mallet is acceptable. 1. Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut 2 turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel nuts from the tire and wheel assembly. 3. Mark the location of the tire and wheel assembly to the hub assembly. 4. Remove the tire and wheel assembly from the vehicle. 5. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. Installation Procedure Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. Notice: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Removal and Installation > Page 7021 1. Install the tire and wheel assembly. Align the locating mark of the tire and wheel to the hub. Notice: Refer to Fastener Notice in Service Precautions. Important: Tighten the nuts evenly and alternately in order to avoid excessive runout. 2. Install the wheel nuts. ^ Tighten the nuts in a cries-cross pattern to 140 Nm (100 ft. lbs.). 3. Remove the safety stands and lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Removal and Installation > Page 7022 Tires: Service and Repair Tire Mounting and Dismounting Tire Mounting and Dismounting Notice: Use a tire changing machine in order to dismount tires. Do not use hand tools or tire irons alone in order to remove the tire from the wheel. Damage to the tire beads or the wheel rim could result. Notice: Do not scratch or damage the clear coating on aluminum wheels with the tire changing equipment. Scratching the clear coating could cause the aluminum wheel to corrode and the clear coating to peel from the wheel. Notice: Damage to either the tire bead or the wheel mounting holes can result from the use of improper wheel attachment or tire mounting procedures. It takes up to 70 seconds for all of the air to completely exhaust from a large tire. Failure to follow the proper procedures could cause the tire changer to put enough force on the tire to bend the wheel at the mounting surface. Such damage may result in vibration and/or shimmy, and under severe usage lead to wheel cracking. 1. Deflate the tire completely. Important: Rim-clamp European-type tire changers are recommended. 2. Use the tire changer in order to remove the tire from the wheel. 3. Use a wire brush or coarse steel wool in order to remove any rubber, light rust or corrosion from the wheel bead seats. Notice: When mounting the tires, use an approved tire mounting lubricant. DO NOT use silicon or corrosive base compounds to lubricate the tire bead and the wheel rim. A silicon base compound can cause the tire to slip on the rim. A corrosive type compound can cause tire or rim deterioration. 4. Apply GM P/N 12345884 (Canadian P/N 5728223) or equivalent to the tire bead and the wheel rim. 5. Use the tire changer in order to install the tire to the wheel. Caution: To avoid serious personal injury, do not stand over tire when inflating. The bead may break when the bead snaps over the safety hump. Do not exceed 275 kPa (40 psi) pressure when inflating any tire if beads are not seated. If 275 kPa (40 psi) pressure will not seat the beads, deflate, relubricate the beads and reinflate. Overinflation may cause the bead to break and cause serious personal injury. 6. Inflate the tire to the proper air pressure. 7. Ensure that the locating rings are visible on both sides of the tire in order to verify that the tire bead is fully seated on the wheel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Removal and Installation > Page 7023 Tires: Service and Repair Tire Repair Tire Repair Many different materials and techniques are available on the market in order to repair tires. Not all of the materials and techniques work on some types of tires. Tire manufacturers have published detailed instructions on how and when to repair tires. Obtain the instructions from the manufacturer. If the vehicle is equipped with a compact spare tire, do not repair the compact spare. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Removal and Installation > Page 7024 Tires: Service and Repair Tire Rotation Tire Rotation Rotate the tires and wheels at frequent intervals to equalize wear. In addition to scheduled rotation, rotate the tire and wheel whenever uneven tire wear is noticed. Radial tires tend to wear faster in the shoulder area, particularly in front positions. Radial tires in non-drive locations may develop an irregular wear pattern that may increase tire noise. This makes regular rotation especially necessary. Always use a 4-wheel rotation. After rotation, check the wheel nuts for specified torque. Then, set the tire pressure. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Service and Repair > Tire and Wheel Removal and Installation > Page 7025 Tires: Service and Repair Tire and Wheel Rotation and Inspection TIRE AND WHEEL INSPECTION AND ROTATION Tires should be rotated every 8 000-13 000 km (5,000-8,000 mi). Any time you notice unusual wear, rotate the tires as soon as possible and test the wheel alignment. Also inspect for damaged tires or wheels. The purpose of regular rotation is to achieve more uniform wear for all tires on the vehicle. The first rotation is the most important. Refer to Scheduled Maintenance for scheduled rotation intervals. When rotating your tires, always use the correct rotation pattern shown here. Do not include the compact spare tire in your tire rotation. After the tires have been rotated, adjust the front and rear inflation pressures Refer to Tire Placard. Reset the Tire Inflation Monitor System. Ensure that all wheel nuts are properly tightened. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: Customer Interest Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 7034 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 7035 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 7036 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: Customer Interest Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 7041 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: Customer Interest Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 7046 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 7047 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 7048 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 7054 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 7055 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 7056 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 7061 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 7066 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 7067 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) Wheels: All Technical Service Bulletins Wheels/Tires - Tire Radial Force Variation (RFV) INFORMATION Bulletin No.: 00-03-10-006F Date: May 04, 2010 Subject: Information on Tire Radial Force Variation (RFV) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X 2000-2005 Saturn L Series 2003-2007 Saturn ION Supercede: This bulletin is being revised to considerably expand the available information on Radial Force Variation (RFV) and should be reviewed in whole. Please discard Corporate Bulletin Number 00-03-10-006E (Section 03 - Suspension). Important - Before measuring tires on equipment such as the Hunter GSP9700, the vehicle MUST be driven a minimum of 16 km (10 mi) to ensure removal of any flat-spotting. Refer to Corporate Bulletin Number 03-03-10-007E - Tire/Wheel Characteristics of GM Original Equipment Tires. - Equipment such as the Hunter GSP9700 MUST be calibrated prior to measuring tire/wheel assemblies for each vehicle. The purpose of this bulletin is to provide guidance to GM dealers when using tire force variation measurement equipment, such as the Hunter GSP9700. This type of equipment can be a valuable tool in diagnosing vehicle ride concerns. The most common ride concern involving tire radial force variation is highway speed shake on smooth roads. Tire related smooth road highway speed shake can be caused by three conditions: imbalance, out of round and tire force variation. These three conditions are not necessarily related. All three conditions must be addressed. Imbalance is normally addressed first, because it is the simpler of the three to correct. Off-vehicle, two plane dynamic wheel balancers are readily available and can accurately correct any imbalance. Balancer calibration and maintenance, proper attachment of the wheel to the balancer, and proper balance weights, are all factors required for a quality balance. However, a perfectly balanced tire/wheel assembly can still be "oval shaped" and cause a vibration. Before balancing, perform the following procedures. Tire and Wheel Diagnosis 1. Set the tire pressure to the placard values. 2. With the vehicle raised, ensure the wheels are centered on the hub by loosening all wheel nuts and hand-tightening all nuts first by hand while shaking the wheel, then torque to specifications using a torque wrench, NOT a torque stick. 3. Visually inspect the tires and the wheels. Inspect for evidence of the following conditions and correct as necessary: - Missing balance weights - Bent rim flange - Irregular tire wear - Incomplete bead seating - Tire irregularities (including pressure settings) - Mud/ice build-up in wheel - Stones in the tire tread - Remove any aftermarket wheels and/or tires and restore vehicle to original condition prior to diagnosing a smooth road shake condition. 4. Road test the vehicle using the Electronic Vibration Analyzer (EVA) essential tool. Drive for a sufficient distance on a known, smooth road surface to duplicate the condition. Determine if the vehicle is sensitive to brake apply. If the brakes are applied lightly and the pulsation felt in the steering wheel increases, refer to the Brakes section of the service manual that deals with brake-induced pulsation. If you can start to hear the vibration as a low boom noise (in addition to feeling it), but cannot see it, the vehicle likely has a first order (one pulse per propshaft revolution) driveline vibration. Driveline first order vibrations are high enough in frequency that most humans can start to hear them at highway speeds, but are too high to be able to be easily seen. These issues can be caused by driveline imbalance or misalignment. If the vehicle exhibits this low boom and the booming pulses in-and-out on a regular basis (like a throbbing), chances are good that the vehicle could have driveline vibration. This type Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 7072 of vibration is normally felt more in the "seat of the pants" than the steering wheel. 5. Next, record the Hertz (Hz) reading as displayed by the EVA onto the tire data worksheet found at the end of this bulletin. This should be done after a tire break-in period of at least 16 km (10 mi) at 72 km/h (45 mph) or greater, in order to eliminate any possible tire flat-spotting. This reading confirms what the vehicle vibration frequency is prior to vehicle service and documents the amount of improvement occurring as the result of the various steps taken to repair. Completing the Steering Wheel Shake Worksheet below is required. A copy of the completed worksheet must be saved with the R.O. and a copy included with any parts returned to the Warranty Parts Center for analysis. A reading of 35 to 50 Hz typically indicates a first order propshaft vibration. If this is the situation, refer to Corporate Bulletin Number 08-07-30-044D. Generally, a reading between 10 and 20 Hz indicates a tire/wheel vibration and if this is the reading obtained, continue using this bulletin. If the tire 1st order vibration goes away and stays away during this evaluation, the cause is likely tire flat-spotting. Tire flat-spotting vibration may come and go at any speed over 72 km/h (45 mph) during the first 10 minutes of operation, if vibration continues after 10 minutes of driving at speeds greater than 72 km/h (45 mph), tire flat-spotting can be ruled out as the cause for vibration. 6. If flat-spotting is the cause, provide the explanation that this has occurred due to the vehicle being parked for long periods of time and that the nature of the tire is to take a set. Refer to Corporate Bulletin Number 03-03-10-007E: Information on Tire/Wheel Characteristics (Vibration, Balance, Shake, Flat Spotting) of GM Original Equipment Tires. 7. If the road test indicates a shake/vibration exists, check the imbalance of each tire/wheel assembly on a known, calibrated, off-car dynamic balancer.Make sure the mounting surface of the wheel and the surface of the balancer are absolutely clean and free of debris. Be sure to chose the proper cone/collet for the wheel, and always use the pilot bore for centering. Never center the wheel using the hub-cap bore since it is not a precision machined surface. If any assembly calls for more than 1/4 ounce on either rim flange, remove all balance weights and rebalance to as close to zero as possible. If you can see the vibration (along with feeling it) in the steering wheel (driving straight without your hands on the wheel), it is very likely to be a tire/wheel first order (one pulse per revolution) disturbance. First order disturbances can be caused by imbalance as well as non-uniformities in tires, wheels or hubs. This first order frequency is too low for a human to hear, but if the amplitude is high enough, it can be seen. If a vibration or shake still exists after balancing, any out of round conditions, of the wheel, and force variation conditions of the tire, must be addressed. Equipment such as the Hunter GSP9700 can address both (it is also a wheel balancer). Tire radial force vibration (RFV) can be defined as the amount of stiffness variation the tire will produce in one revolution under a constant load. Radial force variation is what the vehicle feels because the load (weight) of the vehicle is always on the tires. Although free runout of tires (not under load) is not always a good indicator of a smooth ride, it is critical that total tire/wheel assembly runout be within specification. Equipment such as the Hunter GSP9700 loads the tire, similar to on the vehicle, and measures radial force variation of the tire/wheel assembly. Note that the wheel is affecting the tire's RFV measurement at this point. To isolate the wheel, its runout must be measured. This can be easily done on the Hunter, without the need to set up dial indicators. If the wheel meets the runout specification, the tire's RFV can then be addressed. After measuring the tire/wheel assembly under load, and the wheel alone, the machine then calculates (predicts) the radial force variation of the tire. However, because this is a prediction that can include mounting inaccuracies, and the load wheel is much smaller in diameter than used in tire production, this type of service equipment should NOT be used to audit new tires. Rather, it should be used as a service diagnostic tool to minimize radial force variation of the tire/wheel assembly. Equipment such as the Hunter GSP9700 does an excellent job of measuring wheel runout, and of finding the low point of the wheel (for runout) and the high point of the tire (for radial force variation). This allows the tire to be matched mounted to the wheel for lowest tire/wheel assembly force variation. The machine will simplify this process into easy steps. The following assembly radial force variation numbers should be used as a guide: When measuring RFV and match mounting tires perform the following steps. Measuring Wheel Runout and Assembly Radial Force Variation Important The completed worksheet at the end of this bulletin must be attached to the hard copy of the repair order. - Measure radial force variation and radial runout. - If a road force/balancing machine is used, record the radial force variation (RFV) on the worksheet at the end of this bulletin. It may be of benefit to have the lowest RFV assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires onto the subject vehicle. - If a runout/balancing machine is used, record the radial runout of the tire/wheel assemblies on the worksheet at the end of this bulletin. If one or more of the tire/wheel assemblies are more than.040 in (1.02 mm), match mount the tire to the wheel to get below.040 in (1.02 mm). For sensitive customers, readings of 0.030 inch (0.76 mm) or less are preferable, it may also be of benefit to have the lowest runout assembly to the front left corner. If the machine is not available and the EVA data suggests there is an issue, swap the tire and wheel assemblies from the front to the back. Re-check on the EVA and if the problem still exists, test another vehicle to find tires that do not exhibit the same frequency and swap those tires Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 7073 onto the subject vehicle. - After match mounting, the tire/wheel assembly must be rebalanced. If match mounting tires to in-spec wheels produces assembly values higher than these, tire replacement may be necessary. Replacing tires at lower values will probably mean good tires are being condemned. Because tires can sometimes become temporarily flat-spotted, which will affect force variation, it is important that the vehicle be driven at least 16 km (10 mi) prior to measuring. Tire pressure must also be adjusted to the usage pressure on the vehicle's tire placard prior to measuring. Most GM vehicles will tolerate radial force variation up to these levels. However, some vehicles are more sensitive, and may require lower levels. Also, there are other tire parameters that equipment such as the Hunter GSP9700 cannot measure that may be a factor. In such cases, TAC should be contacted for further instructions. Important - When mounting a GM wheel to a wheel balancer/force variation machine, always use the wheel's center pilot hole. This is the primary centering mechanism on all GM wheels; the bolt holes are secondary. Usually a back cone method to the machine should be used. For added accuracy and repeatability, a flange plate should be used to clamp the wheel onto the cone and machine. This system is offered by all balancer manufacturers in GM's dealer program. - Any type of service equipment that removes tread rubber by grinding, buffing or truing is NOT recommended, and may void the tire warranty. However, tires may have been ground by the tire company as part of their tire manufacturing process. This is a legitimate procedure. Steering Wheel Shake Worksheet When diagnosing vibration concerns, use the following worksheet in conjunction with the appropriate Vibration Analysis-Road testing procedure in the Vibration Correction sub-section in SI. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 00-03-10-006F > May > 10 > Wheels/Tires - Tire Radial Force Variation (RFV) > Page 7074 Refer to the appropriate section of SI for specifications and repair procedures that are related to the vibration concern. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels Wheels: All Technical Service Bulletins Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels TECHNICAL Bulletin No.: 05-03-10-003F Date: April 27, 2010 Subject: Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Cast Aluminum Wheels Supercede: This bulletin is being revised to update the model years and the bulletin reference information. Please discard Corporate Bulletin Number 05-03-10-003E (Section 03 - Suspension). Condition Some customers may comment on a low tire pressure condition. Diagnosis of the low tire pressure condition indicates an air leak through the cast aluminum wheel. Cause Porosity in the cast aluminum wheel may be the cause. Notice This bulletin specifically addresses issues related to the wheel casting that may result in an air leak. For issues related to corrosion of the wheel in service, please refer to Corporate Bulletin Number 08-03-10-006C - Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat). Correction 1. Remove the tire and wheel assembly from the vehicle. Refer to the appropriate service procedure in SI. 2. Locate the leaking area by inflating the tire to 276 kPa (40 psi) and dipping the tire/wheel assembly in a water bath, or use a spray bottle with soap and water to locate the specific leak location. Important - If the porosity leak is located in the bead area of the aluminum rim (where the tire meets the rim), the wheel should be replaced. - If two or more leaks are located on one wheel, the wheel should be replaced. 3. If air bubbles are observed, mark the location. - If the leak location is on the tire/rubber area, refer to Corporate Bulletin Number 04-03-10-001F Tire Puncture Repair Procedures for All Cars and Light Duty Trucks. - If the leak is located on the aluminum wheel area, continue with the next step. 4. Inscribe a mark on the tire at the valve stem in order to indicate the orientation of the tire to the wheel. 5. Dismount the tire from the wheel. Refer to Tire Mounting and Dismounting. 6. Remove the tire pressure sensor. Refer to Tire Pressure Sensor removal procedure in SI. 7. Scuff the INSIDE rim surface at the leak area with #80 grit paper and clean the area with general purpose cleaner, such as 3M(R) General Purpose Adhesive Cleaner, P/N 08984, or equivalent. 8. Apply a 3 mm (0.12 in) thick layer of Silicone - Adhesive/Sealant, P/N 12378478 (in Canada, use 88900041), or equivalent, to the leak area. 9. Allow for the adhesive/sealant to dry. Notice Caution must be used when mounting the tire so as not to damage the sealer. Damaging the repair area may result in an air leak. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 05-03-10-003F > Apr > 10 > Tires/Wheels - Low Tire/Leaking Cast Aluminum Wheels > Page 7079 10. Align the inscribed mark on the tire with the valve stem on the wheel. 11. Reinstall the Tire Pressure Sensor. Refer to Tire Pressure Sensor installation procedure in SI. 12. Mount the tire on the wheel. Refer to Tire Mounting and Dismounting. 13. Pressurize the tire to 276 kPa (40 psi) and inspect for leaks. 14. Adjust tire pressure to meet the placard specification. 15. Balance the tire/wheel assembly. Refer to Tire and Wheel Assembly Balancing - Off-Vehicle. 16. Install the tire and wheel assembly onto the vehicle. Refer to the appropriate service procedure in SI. Parts Information Warranty Information (excluding Saab U.S. Models) Important The Silicone - Adhesive/Sealant comes in a case quantity of six. ONLY charge warranty one tube of adhesive/sealant per wheel repair. For vehicles repaired under warranty, use: One leak repair per wheel. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON Wheels: All Technical Service Bulletins Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON TECHNICAL Bulletin No.: 08-03-10-006C Date: April 27, 2010 Subject: Tire Slowly Goes Flat, Tire Air Loss, Low Tire Pressure Warning Light Illuminated, Aluminum Wheel Bead Seat Corrosion (Clean and Resurface Wheel Bead Seat) Models: 2000-2011 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-03-10-006B (Section 03 - Suspension). Condition Some customers may comment on a tire that slowly loses air pressure over a period of days or weeks. Cause Abrasive elements in the environment may intrude between the tire and wheel at the bead seat. There is always some relative motion between the tire and wheel (when the vehicle is driven) and this motion may cause the abrasive particles to wear the wheel and tire materials. As the wear continues, there may also be intrusion at the tire/wheel interface by corrosive media from the environment. Eventually a path for air develops and a 'slow' leak may ensue. This corrosion may appear on the inboard or outboard bead seating surface of the wheel. This corrosion will not be visible until the tire is dismounted from the wheel. Notice This bulletin specifically addresses issues related to wheel bead seat corrosion that may result in an air leak. For issues related to porosity of the wheel casting that may result in an air leak, please refer to Corporate Bulletin Number 05-03-10-006F - Low Tire Pressure, Leaking Cast Aluminum Wheels (Repair with Adhesive Sealant) Correction In most cases, this type of air loss can be corrected by following the procedure below. Important DO NOT replace a wheel for slow air loss unless you have evaluated and/or tried to repair the wheel with the procedure below. Notice The repair is no longer advised or applicable for chromed aluminum wheels. 1. Remove the wheel and tire assembly for diagnosis. Refer to Tire and Wheel Removal and Installation in SI. 2. After a water dunk tank leak test, if you determine the source of the air leak to be around the bead seat of the wheel, dismount the tire to examine the bead seat. Shown below is a typical area of bead seat corrosion.Typical Location of Bead Seat Corrosion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 7084 Important Other forms of slow air leaks are possible. If the body of the tire, valve stem and wheel flange show no signs of air seepage, refer to Corporate Bulletin Number 05-03-10-003D for additional information on possible wheel porosity issues. 3. Bead seat corrosion is identified by what appears like blistering of the wheel finish, causing a rough or uneven surface that is difficult for the tire to maintain a proper seal on. Below is a close-up photo of bead seat corrosion on an aluminum wheel that was sufficient to cause slow air loss. Close-Up of Bead Seat Corrosion 4. If corrosion is found on the wheel bead seat, measure the affected area as shown below. - For vehicles with 32,186 km (20,000 mi) or less, the total allowable combined linear area of repairable corrosion is 100 mm (4 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. - For vehicles that have exceeded 32,186 km (20,000 mi), the total allowable combined linear area of repairable corrosion is 200 mm (8 in) or less. If the total area(s) of corrosion exceed these dimensions, the wheel should be replaced. 5. In order to correct the wheel leak, use a clean-up (fine cut) sanding disc or biscuit to remove the corrosion and any flaking paint. You should remove the corrosion back far enough until you reach material that is stable and firmly bonded to the wheel. Try to taper the edge of any flaking paint as best you can in order to avoid sharp edges that may increase the chance of a leak reoccurring. The photo below shows an acceptable repaired surface. Notice Corrosion that extends up the lip of the wheel, where after the clean-up process it would be visible with the tire mounted, is only acceptable on the inboard flange. The inboard flange is not visible with the wheel assembly in the mounted position. If any loose coatings or corrosion extend to the visible surfaces on the FACE of the wheel, that wheel must be replaced. Important Remove ONLY the material required to eliminate the corrosion from the bead seating surface. DO NOT remove excessive amounts of material. ALWAYS keep the sealing surface as smooth and level as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 7085 Acceptably Prepared (Cleaned-Up) Wheel Surface 6. Once the corrosion has been eliminated, you should coat the repaired area with a commercially available tire sealant such as Patch Brand Bead Sealant or equivalent. Commercially available bead sealants are black rubber-like coatings that will permanently fill and seal the resurfaced bead seat. At 21°C (70°F) ambient temperature, this sealant will set-up sufficiently for tire mounting in about 10 minutes.Coated and Sealed Bead Seat 7. Remount the tire and install the repaired wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in SI. Parts Information Patch Brand Bead Sealer is available from Myers Tires at 1-800-998-9897 or on the web at www.myerstiresupply.com. The one-quart size can of sealer will repair about 20 wheels. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table above. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 08-03-10-006C > Apr > 10 > Tires/Wheels - Tire Slowly Goes Flat/Warning Light ON > Page 7086 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Staining/Pitting/Corrosion INFORMATION Bulletin No.: 00-03-10-002F Date: April 21, 2011 Subject: Chemical Staining, Pitting, Corrosion and/or Spotted Appearance of Chromed Aluminum Wheels Models: 2012 and Prior GM Cars and Trucks Supercede: This bulletin is being revised to update model years, suggest additional restorative products and add additional corrosion information. Please discard Corporate Bulletin Number 00-03-10-002E (Section 03 - Suspension). Important You may give a copy of this bulletin to the customer. What is Chemical Staining of Chrome Wheels? Figure 1 Chemical staining in most cases results from acid based cleaners (refer to Figure 1 for an example). These stains are frequently milky, black, or greenish in appearance. They result from using cleaning solutions that contain acids on chrome wheels. Soap and water is usually sufficient to clean wheels. If the customer insists on using a wheel cleaner they should only use one that specifically states that it is safe for chromed wheels and does not contain anything in the following list. (Dealers should also survey any products they use during prep or normal cleaning of stock units for these chemicals.) - Ammonium Bifluoride (fluoride source for dissolution of chrome) - Hydrofluoric Acid (directly dissolves chrome) - Hydrochloric Acid (directly dissolves chrome) - Sodium Dodecylbenzenesulfonic Acid - Sulfamic Acid - Phosphoric Acid - Hydroxyacetic Acid Notice Many wheel cleaner instructions advise to take care to avoid contact with painted surfaces. Most customers think of painted surfaces as the fenders, quarter panels and other exterior sheet metal. Many vehicles have painted brake calipers. Acidic wheel cleaners may craze, crack, or discolor the paint on the brake calipers. Damage from wheel cleaners is not covered under the vehicle new car warranty. Soap and water applied with a soft brush is usually all that is required to clean the calipers. Whenever any wheel cleaner is used, it must be THOROUGHLY rinsed off of the wheel with clean, clear water. Special care must be taken to rinse under the hub cap, balance weights, wheel nuts, lug nut caps, between the wheel cladding and off the back side of the wheel. Wheels returned to the Warranty Parts Center (WPC) that exhibit damage from wheel cleaners most often have the damage around and under the wheel weight where the cleaner was incompletely flushed away. Notice Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 7096 Do not use cleaning solutions that contain hydrofluoric, oxalic and most other acids on chrome wheels (or any wheels). If the customer is unsure of the chemical make-up of a particular wheel cleaner, it should be avoided. For wheels showing signs of milky staining from acidic cleaners, refer to Customer Assistance and Instructions below. Warranty of Stained Chrome Wheels Stained wheels are not warrantable. Most acid based cleaners will permanently stain chrome wheels. Follow-up with dealers has confirmed that such cleaners were used on wheels that were returned to the Warranty Parts Center (WPC). Any stained wheels received by the WPC will be charged back to the dealership. To assist the customer, refer to Customer Assistance and Instructions below. Pitting or Spotted Appearance of Chrome Wheels Figure 2 A second type or staining or finish disturbance may result from road chemicals, such as calcium chloride used for dust control of unpaved roads. The staining will look like small pitting (refer to Figure 2). This staining will usually be on the leading edges of each wheel spoke, but may be uniformly distributed. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Important Road chemicals, such as calcium chloride used for dust control of unpaved roads, can also stain chrome wheels. The staining will look like small pitting. This staining will usually be on the leading edges of each wheel spoke. This is explained by the vehicle traveling in the forward direction while being splashed by the road chemical. If a vehicle must be operated under such conditions, the chrome wheels should be washed with mild soap and water and thoroughly rinsed as soon as conveniently possible. Warranty of Pitted or Spotted Chrome Wheels Wheels returned with pitting or spotting as a result of road chemicals may be replaced one time. Damage resulting from contact with these applied road chemicals is corrosive to the wheels finish and may cause damage if the wheels are not kept clean. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean if they are operating the vehicle in an area that applies calcium chloride or other dust controlling chemicals! "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). "Stardust" Corrosion of Chrome Wheels Figure 3 A third type of finish disturbance results from prolonged exposure to brake dust and resultant penetration of brake dust through the chrome. As brakes are applied hot particles of brake material are thrown off and tend to be forced through the leading edge of the wheel spoke windows by airflow. These Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 7097 hot particles embed themselves in the chrome layer and create a small pit. If the material is allowed to sit on the wheel while it is exposed to moisture or salt, it will corrode the wheel beneath the chrome leaving a pit or small blister in the chrome. Heavy brake dust build-up should be removed from wheels by using GM Chrome Cleaner and Polish, P/N 1050173 (in Canada use 10953013). For moderate cleaning, light brake dust build-up or water spots use GM Swirl Remover Polish, P/N 12377965 (in Canada, use Meguiars Plast-X(TM) Clear Plastic Cleaner and Polish #G12310C**). After cleaning, the wheel should be waxed using GM Cleaner Wax, P/N 12377966 (in Canada, use Meguiars Cleaner Wax #M0616C**), which will help protect the wheel from brake dust and reduce adhesion of any brake dust that gets on the wheel surface. For general maintenance cleaning, PEEK Metal Polish† may be used. It will clean and shine the chrome and leave behind a wax coating that may help protect the finish. Warranty of Stardust Corroded Chrome Wheels Wheels returned with pitting or spotting as a result of neglect and brake dust build-up may be replaced one time. Important Notify the customer that this is a one time replacement. Please stress to the customer the vital importance of keeping the wheels clean and free of prolonged exposure to brake dust build-up. "GM of Canada" dealers require prior approval by the District Manager - Customer Care and Service Process (DM-CCSP). Customer Assistance and Instructions GM has looked for ways customers may improve the appearance of wheels damaged by acidic cleaners. The following product and procedure has been found to dramatically improve the appearance of stained wheels. For wheels that have milky stains caused by acidic cleaners try the following: Notice THE 3M CHROME AND METAL POLISH REQUIRED FOR THIS PROCEDURE IS AN EXTREMELY AGGRESSIVE POLISH/CLEANER. THE WHEELS MUST BE CLEANED BEFORE APPLICATION TO AVOID SCRATCHING THE WHEEL SURFACE. THIS PRODUCT WILL REDUCE THE THICKNESS OF THE CHROME PLATING ON THE WHEEL AND IF USED INCORRECTLY OR EXCESSIVELY MAY REMOVE THE CHROME PLATING ALL TOGETHER, EXPOSING A LESS BRIGHT AND BRASSY COLORED SUB-LAYER. FOLLOW INSTRUCTIONS EXACTLY. 1. Wash the wheels with vigorously with soap and water. This step will clean and may reduce wheel staining. Flood all areas of the wheel with water to rinse. 2. Dry the wheels completely. Notice Begin with a small section of the wheel and with light pressure buff off polish and examine results. ONLY apply and rub with sufficient force and time to remove enough staining that you are satisfied with the results. Some wheels may be stained to the extent that you may only achieve a 50% improvement while others may be able to be restored to the original lustre. IN ALL CASES, only apply until the results are satisfactory. 3. Apply 3M Chrome and Metal Polish #39527* with a clean terry cloth towel. As you apply the polish, the staining will be diminished. 4. When dry, buff off the polish with a clean portion of the towel. 5. Repeat application of the 3M Chrome and Metal Polish until satisfied with the results. If continued applications fail to improve the appearance further discontinue use. This procedure will improve the appearance of the wheels and may, with repeated applications, restore the finish dramatically. For wheels that exhibit spotting from road chemicals the above procedure may marginally improve the condition but will not restore the finish or remove the pitting. In this type of staining the wheel finish has actually been removed in spots and no manner of cleaning will restore the finish. †*We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 00-03-10-002F > Apr > 11 > Wheels - Chrome Wheel Staining/Pitting/Corrosion > Page 7098 *This product is currently available from 3M. To obtain information for your local retail location please call 3M at 1-888-364-3577. **This product is currently available from Meguiars (Canada). To obtain information for your local retail location please call Meguiars at 1-800-347-5700 or at www.meguiarscanada.com. ^ This product is currently available from Tri-Peek International. To obtain information for your local retail location please call Tri-Peek at 1-877-615-4272 or at www.tripeek.com. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels Wheels: All Technical Service Bulletins Wheels/Tires - Refinishing Aluminum Wheels INFORMATION Bulletin No.: 99-08-51-007E Date: March 17, 2011 Subject: Refinishing Aluminum Wheels Models: 2012 and Prior GM Passenger Cars and Trucks Supercede: This bulletin is being revised to add additional model years. Please discard Corporate Bulletin Number 99-08-51-007D (Section 08 - Body and Accessories). This bulletin updates General Motor's position on refinishing aluminum wheels. GM does not endorse any repairs that involve welding, bending, straightening or re-machining. Only cosmetic refinishing of the wheel's coatings, using recommended procedures, is allowed. Evaluating Damage In evaluating damage, it is the GM Dealer's responsibility to inspect the wheel for corrosion, scrapes, gouges, etc. The Dealer must insure that such damage is not deeper than what can be sanded or polished off. The wheel must be inspected for cracks. If cracks are found, discard the wheel. Any wheels with bent rim flanges must not be repaired or refinished. Wheels that have been refinished by an outside company must be returned to the same vehicle. The Dealer must record the wheel ID stamp or the cast date on the wheel in order to assure this requirement. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. Aluminum Wheel Refinishing Recommendations - Chrome-plated aluminum wheels Re-plating these wheels is not recommended. - Polished aluminum wheels These wheels have a polyester or acrylic clearcoat on them. If the clearcoat is damaged, refinishing is possible. However, the required refinishing process cannot be performed in the dealer environment. Refer to Refinisher's Responsibility - Outside Company later in this bulletin. - Painted aluminum wheels These wheels are painted using a primer, color coat, and clearcoat procedure. If the paint is damaged, refinishing is possible. As with polished wheels, all original coatings must be removed first. Media blasting is recommended. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for the re-painting of this type of wheel. - Bright, machined aluminum wheels These wheels have a polyester or acrylic clearcoat on them. In some cases, the recessed "pocket" areas of the wheel may be painted. Surface refinishing is possible. The wheel must be totally stripped by media blasting or other suitable means. The wheel should be resurfaced by using a sanding process rather than a machining process. This allows the least amount of material to be removed. Important Do not use any re-machining process that removes aluminum. This could affect the dimensions and function of the wheel. Painting is an option to re-clearcoating polished and bright machined aluminum wheels. Paint will better mask any surface imperfections and is somewhat more durable than clearcoat alone. GM recommends using Corsican SILVER WAEQ9283 for a fine "aluminum-like" look or Sparkle SILVER WA9967 for a very bright look. As an option, the body color may also be used. When using any of the painting options, it is recommended that all four wheels be refinished in order to maintain color uniformity. Refer to GM Aluminum Refinishing Bulletin #53-17-03A for specific procedures and product recommendations. Refinisher's Responsibility - Outside Company Important Some outside companies are offering wheel refinishing services. Such refinished wheels will be permanently marked by the refinisher and are warranted by the refinisher. Any process that re-machines or otherwise re-manufactures the wheel should not be used. A refinisher's responsibility includes inspecting for cracks using the Zyglo system or the equivalent. Any cracked wheels must not be refinished. No welding, hammering or reforming of any kind is allowed. The wheel ID must be recorded and follow the wheel throughout the process in order to assure that the same wheel is returned. A plastic media blast may be used for clean up of the wheel. Hand and/or lathe sanding of the machined surface and the wheel window is allowed. Material removal, though, must be kept to a minimum. Re-machining of the wheel is not allowed. Paint and/or clear coat must not be present on the following surfaces: the nut chamfers, the wheel mounting surfaces and the wheel pilot hole. The refinisher must permanently ID stamp the wheel and warrant the painted/clearcoated surfaces for a minimum of one year or the remainder of the new vehicle warranty, whichever is Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 99-08-51-007E > Mar > 11 > Wheels/Tires Refinishing Aluminum Wheels > Page 7103 longer. Important Whenever a wheel is refinished, the mounting surface and the wheel nut contact surfaces must not be painted or clearcoated. Coating these surfaces could affect the wheel nut torque. When re-mounting a tire on an aluminum wheel, coated balance weights must be used in order to reduce the chance of future cosmetic damage. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions Wheels: All Technical Service Bulletins Wheels - Changing Procedures/Precautions INFORMATION Bulletin No.: 06-03-10-010A Date: June 09, 2010 Subject: Information on Proper Wheel Changing Procedures and Cautions Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER Models 2005-2009 Saab 9-7X 2005-2009 Saturn Vehicles Attention: Complete wheel changing instructions for each vehicle line can be found under Tire and Wheel Removal and Installation in Service Information (SI). This bulletin is intended to quickly review and reinforce simple but vital procedures to reduce the possibility of achieving low torque during wheel installation. Always refer to SI for wheel lug nut torque specifications and complete jacking instructions for safe wheel changing. Supercede: This bulletin is being revised to include the 2011 model year and update the available special tool list. Please discard Corporate Bulletin Number 06-03-10-010 (Section 03 Suspension). Frequency of Wheel Changes - Marketplace Driven Just a few years ago, the increasing longevity of tires along with greater resistance to punctures had greatly reduced the number of times wheels were removed to basically required tire rotation intervals. Today with the booming business in accessory wheels/special application tires (such as winter tires), consumers are having tire/wheel assemblies removed - replaced - or installed more than ever. With this increased activity, it opens up more of a chance for error on the part of the technician. This bulletin will review a few of the common concerns and mistakes to make yourself aware of. Proper Servicing Starts With the Right Tools The following tools have been made available to assist in proper wheel and tire removal and installation. - J 41013 Rotor Resurfacing Kit (or equivalent) - J 42450-A Wheel Hub Resurfacing Kit (or equivalent) Corroded Surfaces One area of concern is corrosion on the mating surfaces of the wheel to the hub on the vehicle. Excessive corrosion, dirt, rust or debris built up on these surfaces can mimic a properly tightened wheel in the service stall. Once the vehicle is driven, the debris may loosen, grind up or be washed away from water splash. This action may result in clearance at the mating surface of the wheel and an under-torqued condition. Caution Before installing a wheel, remove any buildup on the wheel mounting surface and brake drum or brake disc mounting surface. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This may cause a wheel to come off when the vehicle is moving, possibly resulting in a loss of control or personal injury. Whenever you remove the tire/wheel assemblies, you must inspect the mating surfaces. If corrosion is found, you should remove the debris with a die grinder equipped with a fine sanding pad, wire brush or cleaning disc. Just remove enough material to assure a clean, smooth mating surface. The J 41013 (or equivalent) can be used to clean the following surfaces: - The hub mounting surface - The brake rotor mounting surface - The wheel mounting surface Use the J 42450-A (or equivalent) to clean around the base of the studs and the hub. Lubricants, Grease and Fluids Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 7108 Some customers may use penetrating oils, grease or other lubricants on wheel studs to aid in removal or installation. Always use a suitable cleaner/solvent to remove these lubricants prior to installing the wheel and tire assemblies. Lubricants left on the wheel studs may cause improper readings of wheel nut torque. Always install wheels to clean, dry wheel studs ONLY. Notice Lubricants left on the wheel studs or vertical mounting surfaces between the wheel and the rotor or drum may cause the wheel to work itself loose after the vehicle is driven. Always install wheels to clean, dry wheel studs and surfaces ONLY. Beginning with 2011 model year vehicles, put a light coating of grease, GM P/N 1051344 (in Canada, P/N 9930370), on the inner surface of the wheel pilot hole to prevent wheel seizure to the axle or bearing hub. Wheel Stud and Lug Nut Damage Always inspect the wheel studs and lug nuts for signs of damage from crossthreading or abuse. You should never have to force wheel nuts down the stud. Lug nuts that are damaged may not retain properly, yet give the impression of fully tightening. Always inspect and replace any component suspected of damage. Tip Always start wheel nuts by hand! Be certain that all wheel nut threads have been engaged BEFORE tightening the nut. Important If the vehicle has directional tread tires, verify the directional arrow on the outboard side of the tire is pointing in the direction of forward rotation. Wheel Nut Tightening and Torque Improper wheel nut tightening can lead to brake pulsation and rotor damage. In order to avoid additional brake repairs, evenly tighten the wheel nuts to the proper torque specification as shown for each vehicle in SI. Always observe the proper wheel nut tightening sequence as shown below in order to avoid trapping the wheel on the wheel stud threads or clamping the wheel slightly off center resulting in vibration. The Most Important Service You Provide While the above information is well known, and wheel removal so common, technicians run the risk of becoming complacent on this very important Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 06-03-10-010A > Jun > 10 > Wheels - Changing Procedures/Precautions > Page 7109 service operation. A simple distraction or time constraint that rushes the job may result in personal injury if the greatest of care is not exercised. Make it a habit to double check your work and to always side with caution when installing wheels. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 04-03-10-012B > Feb > 08 > Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Wheels: All Technical Service Bulletins Wheels - Chrome Wheel Brake Dust Accumulation/Pitting Bulletin No.: 04-03-10-012B Date: February 01, 2008 INFORMATION Subject: Pitting and Brake Dust on Chrome wheels Models: 2008 and Prior GM Passenger Cars and Trucks (including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 04-03-10-012A (Section 03 - Suspension). Analysis of Returned Wheels Chrome wheels returned under the New Vehicle Limited Warranty for pitting concerns have recently been evaluated. This condition is usually most severe in the vent (or window) area of the front wheels. This "pitting" may actually be brake dust that has been allowed to accumulate on the wheel. The longer this accumulation builds up, the more difficult it is to remove. Cleaning the Wheels In all cases, the returned wheels could be cleaned to their original condition using GM Vehicle Care Cleaner Wax, P/N 12377966 (in Canada, P/N 10952905). When using this product, you should confine your treatment to the areas of the wheel that show evidence of the brake dust build-up. This product is only for use on chromed steel or chromed aluminum wheels. Parts Information Warranty Information Wheel replacement for this condition is NOT applicable under the terms of the New Vehicle Limited Warranty. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Page 7114 Wheels: Description and Operation Replacement Wheels Description Replace the wheel if any of the following conditions exist: ^ The wheel exhibits excessive runout. ^ The wheel is bent. ^ The wheel is cracked. ^ The wheel is severely rusted. ^ The wheel is severely corroded. Important: Air leaks caused by porosity on aluminum wheels are repairable. ^ The wheel leaks air. Caution: If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the wheel bolt(s), install only new GM original equipment parts. Installation of used parts or non-GM original equipment parts may cause the wheel to loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle control resulting in personal injury. Notice: The use of non-GM original equipment wheels may cause: ^ Damage to the wheel bearing, the wheel fasteners and the wheel ^ Tire damage caused by the modified clearance to the adjacent vehicle components ^ Adverse vehicle steering stability caused by the modified scrub radius ^ Damage to the vehicle caused by the modified ground clearance ^ Speedometer and odometer inaccuracy Replace the wheel, the wheel studs and the wheel/nuts, or the wheel bolts if applicable, if any of the following conditions exist: ^ The wheel has elongated bolt holes. ^ The wheel/nuts, or bolts if applicable, loosen repeatedly. Steel wheel identification is stamped into the wheel near the valve stem. Aluminum wheel identification is cast into the inboard side of the wheel. Steel Wheel Repair Description Notice: Do not heat wheels in an attempt to soften them for straightening or repair damage from striking curbs, etc. Do not weld wheels. The alloy used in these wheels is heat-treated and uncontrolled heating from welding affects the properties of the material. Notice: The use of tubes in tubeless tires is not a recommended repair due to the fact that speed ratings are greatly reduced. You can repair porosity in aluminum wheels. If leaks are found in a steel wheel, replace the wheel with a wheel of original equipment quality. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair Wheels: Service and Repair Aluminum Wheel Porosity Repair Aluminum Wheel Porosity Repair 1. Remove the tire and wheel. 2. Inflate the tire to the manufactures specified pressure as stated on the tire. 3. Submerge the tire/wheel into a water bath in order to locate the leak. 4. Inscribe a mark on the wheel in order to indicate the leak areas. 5. Inscribe a mark on the tire at the valve stem in order to Indicate the orientation of the tire to the wheel. 6. Remove the tire from the wheel. Important: Do not damage the exterior surface of the wheel. 7. Use number 80 grit sandpaper to scuff the inside of the rim surface at the leak area. 8. Use general purpose cleaner such as EMS, P/N 08984 or equivalent, to clean the leak area. 9. Apply 3 mm (0.12 in.) thick layer of adhesive/sealant, GM P/N 12378478 (Canadian P/N 88900041) or equivalent, to the leak area. 10. Allow for the adhesive/sealant to dry. 11. Align the inscribed mark on the tire with the valve stem on the wheel. 12. Install the tire to the wheel. 13. Inflate the tire to the manufactures specified pressure as stated on the tire. 14. Submerge the tire/wheel into a water bath in order ensure the leak is sealed. 15. Balance the tire and wheel. 16. Install the tire and wheel. 17. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 7117 Wheels: Service and Repair Aluminum Wheel Refinishing Aluminum Wheel Refinishing Finish Damage Evaluation Procedure Important: ^ If the wheels are chrome-plated, do not re-plate or refinish the wheels. ^ If the wheels are polished aluminum, do not refinish the wheels in the dealer environment. Utilize a refinisher that meets manufacturer guidelines. 1. Inspect the wheels for damage from uncoated wheel balance weights or from automatic car wash facilities. 2. Inspect the wheels for the following conditions: ^ Corrosion ^ Scrapes ^ Gouges 3. Verify the damage is not deeper than what sanding can remove. 4. Inspect the wheels for cracks. If a wheel has cracks, discard the wheel. 5. Inspect the wheels for bent rim flanges. If a rim flange is bent, discard the wheel. Refinishing Procedure Caution: To avoid serious personal injury when applying any two part component paint system, follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions may cause lung irritation and allergic respiratory reaction. 1. Remove the tire and wheel assembly from the vehicle. 2. Remove the balance weights from the wheel. 3. Remove the tire from the wheel. 4. Use a suitable cleaner in order to remove the following contaminants from the wheel: ^ Lubricants ^ Wax ^ Dirt Important: ^ Do not re-machine the wheel. ^ Do not use chemicals in order to strip the paint from the wheel. 5. Use plastic media blasting in order to remove the paint from the wheel. 6. If the wheel had a machined aluminum finish, spin the wheel and use sand paper in order to restore the circular machined appearance. Important: The wheel mounting surface and the wheel nut contact surface must remain free of paint. 7. Mask the wheel mounting surface and the wheel nut contact surface. 8. Follow the paint manufacturer's instructions for painting the wheel. 9. Unmask the wheel. 10. Install a new valve stem. Important: Use new coated balance weights in order to balance the wheel. 11. Install the tire to the wheel. 12. Use a suitable cleaner in order to remove the following contaminants from the wheel mounting surface: ^ Corrosion ^ Overspray ^ Dirt 13. Install the tire and wheel assembly to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 7118 Wheels: Service and Repair Tire and Wheel Removal and Installation Tire and Wheel Removal and Installation ^ Tools Required J 39544-KIT Complete Torque Socket Set Removal Procedure Caution: If penetrating oil gets on the vertical surfaces between the wheel and the rotor or drum it could cause the wheel to work loose as the vehicle is driven, resulting in loss of control and an injury accident Notice: Never use heat to loosen a tight wheel. It can shorten the life of the wheel, studs, or hub and bearing assemblies. Wheel nuts must be tightened in sequence and to the specified torque to avoid bending the wheel or rotor. Notice: Improperly tightened wheel nuts can lead to brake pulsation and rotor damage. In order to avoid expensive brake repairs, evenly tighten the wheel nuts to the proper torque specification. Notice: Removing wheels can be difficult because of foreign material or a tight fit between the wheel center hole and the hub or rotor. Excessive force, such as hammering on the wheel or tire, can cause damage. Slightly tapping the tire side wall with a rubber mallet is acceptable. 1. Tighten all wheel nuts on the affected wheel. 2. Loosen each wheel nut 2 turns. 3. Rock the vehicle from side to side in order to loosen the wheel. If this does not loosen the wheel, rock the vehicle front to back applying quick hard jabs to the brake pedal to loosen the wheel. 4. Repeat this procedure if the wheel does not break free. 1. Raise the vehicle. Support the vehicle with suitable safety stands. Refer to Vehicle Lifting. 2. Remove the wheel nuts from the tire and wheel assembly. 3. Mark the location of the tire and wheel assembly to the hub assembly. 4. Remove the tire and wheel assembly from the vehicle. 5. Clean the wheel nuts, studs and the wheel and rotor mounting surfaces. Installation Procedure Caution: Before installing the wheels, remove any buildup of corrosion on the wheel mounting surface and brake drum or disc mounting surface by scraping and wire brushing. Installing wheels with poor metal-to-metal contact at the mounting surfaces can cause wheel nuts to loosen. This can cause a wheel to come off when the vehicle is moving, causing loss of control and possibly personal injury. Notice: A torque wrench or J 39544 must be used to ensure that wheel nuts are tightened to specification. Never use lubricants or penetrating fluids on wheel stud, nuts, or mounting surfaces, as this can raise the actual torque on the nut without a corresponding torque reading on the torque wrench. Wheel nuts, studs, and mounting surfaces must be clean and dry. Failure to follow these instructions could result in wheel, nut, and/or stud damage. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service and Repair > Aluminum Wheel Porosity Repair > Page 7119 1. Install the tire and wheel assembly. Align the locating mark of the tire and wheel to the hub. Notice: Refer to Fastener Notice in Service Precautions. Important: Tighten the nuts evenly and alternately in order to avoid excessive runout. 2. Install the wheel nuts. ^ Tighten the nuts in a cries-cross pattern to 140 Nm (100 ft. lbs.). 3. Remove the safety stands and lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications Wheel Bearing: Mechanical Specifications Front Wheel Bearing/Hub Bolts ............................................................................................................................................................. 130 Nm (96 ft. lbs.) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Mechanical Specifications > Page 7124 Wheel Bearing: Fluid Type Specifications FRONT WHEEL BEARINGS Wheel bearing lubricant meeting requirements of NLGI # 2, Category GC or GC-LB (GM Part No. U.S. 1051344, in Canada 993037). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 7125 Wheel Bearings Diagnosis Step 1-7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Wheel Bearing/Hub Replacement - Front ^ Tools Required J 42129 Wheel Hub Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Disconnect the wheel speed sensor electrical connector (2), if equipped. 4. Remove the wheel speed sensor electrical connector from the bracket, if equipped. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7128 5. Remove the front wheel drive shaft nut (2). Insert a drift or flat bladed tool (1) into the caliper and rotor to prevent from turning. 6. Remove the brake rotor. 7. Use 3 wheel nuts in order to attach the J 42129 to the wheel bearing/hub. 8. Use the J 42129 in order to push the wheel drive shaft out of the wheel bearing/hub. 9. Remove and DISCARD the wheel bearing/hub bolts. Remove the J 42129 from the hub. Important: Ensure that the wheel drive shaft outer seal/boot is not damaged. 10. Remove the wheel bearing/hub and splash shield-noting the position of the shield for reinstallation. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7129 1. Install the wheel bearing/hub with the splash shield as noted during removal. Caution: These fasteners MUST be replaced with new fasteners anytime they become loose or are removed. Failure to replace these fasteners after they become loose or are removed may cause loss of vehicle control and personal injury. Notice: Refer to Fastener Notice in Service Precautions. 2. Install NEW wheel bearing/hub bolts. ^ Tighten the NEW wheel bearing/hub bolts to 130 Nm (96 ft. lbs.). 3. Install the brake rotor and caliper. 4. Install the front wheel drive shaft nut. Insert a drift on a flat bladed tool into caliper and rotor to prevent the rotor from turning. ^ Tighten the front wheel drive shaft nut to 160 Nm (118 ft. lbs.). Important: Ensure that the connector clip engages the bracket properly. 5. Install the wheel speed sensor electrical connector to the bracket, if equipped. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7130 6. Connect the wheel speed sensor electrical connector (2), if equipped. 7. Install the tire and wheel. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7131 Wheel Bearing: Service and Repair Rear Wheel Bearing/Hub Replacement - Rear Removal Procedure Important: The wheel bearing in the rear wheel hub is integrated into one unit. The hub is non-serviceable. If the hub and/or bearing is damaged, replace the complete hub and bearing assembly. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the tires and wheels. 3. Remove the brake rotor. 4. Remove the ABS electrical connector from the wheel speed sensor (1), if equipped. 5. Remove the park brake cable from the park brake actuator. 6. Remove the mounting bolts from the rear bearing/hub. 7. Remove the wheel bearing/hub and park brake assembly from the knuckle. 8. Remove the park brake actuator from the rear wheel bearing/hub. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 7132 1. Install the park brake actuator to the rear wheel bearing/hub. 2. install the wheel bearing/hub and park brake assembly to the knuckle. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the wheel bearing/hub-to-knuckle bolts. ^ Tighten the bolts to 75 Nm (55 ft. lbs.). 4. Install the park brake cable to the park brake actuator. 5. Install the ABS electrical connector to the wheel speed sensor (1), if equipped. 6. Install the brake rotor. 7. Install the tires and wheels. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component Information > Specifications Axle Nut: Specifications Front Drive Shaft Nut ........................................................................................................................... ................................................... 160 N.m (118 lb ft) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: Customer Interest Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels - Plastic Wheel Nut Covers Loose/Missing > Page 7145 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing Wheel Fastener: All Technical Service Bulletins Wheels - Plastic Wheel Nut Covers Loose/Missing Bulletin No.: 01-03-10-009A Date: July 27, 2004 TECHNICAL Subject: Plastic Wheel Nut Covers Missing and/or Loose (Replace Missing Covers and Add Sealant to All Covers) Models: 2005 and All Prior Passenger Cars (Except All Cadillac Models and Pontiac GTO) with Plastic Wheel Nut Covers Supercede: This bulletin is being revised to add additional models years. Please discard Corporate Bulletin Number 01-03-10-009. Condition Some customers may comment that the plastic wheel nut covers are missing and/or loose. Correction Important: ^ DO NOT USE a silicone-based adhesive. ^ Do not apply the *permatex(R) around the threads in a circular pattern. ^ Apply a single bead across the threads approximately 10 mm (0.4 in) in length, 5 mm (0.2 in) in height and 5 mm (0.2 in) in width. Replace any missing plastic wheel nut covers with the appropriate covers and apply Permatex(R) # 2 Form A Gasket Sealant(R) to the threads of all the plastic wheel nut covers. Tighten finger tight plus a 1/4 turn with a hand wrench. *We believe this source and their products to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any other such items which may be available from other sources. Permatex(R) # 2 Form A Gasket Sealant(R) part numbers (available at your local parts supplier) ^ P/N 80009 (2A/2AR) - 44 ml (1.5 oz) tube boxed ^ P/N 80015 (2AR) - 44 ml (1.5 oz) tube carded ^ P/N 80010 (2B/2BR) - 89 ml (3 oz) tube boxed ^ P/N 80016 (2BR) - 89 ml (3 oz) tube carded ^ P/N 80011 (2C) - 325 ml (11 oz) tube boxed Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 01-03-10-009A > Jul > 04 > Wheels Plastic Wheel Nut Covers Loose/Missing > Page 7151 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 7152 Wheel Fastener: Specifications Wheel Nuts .......................................................................................................................................... ................................................. 140 Nm (100 ft. lbs.) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 7153 Wheel Nut Torque Sequence Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Page 7154 Wheel Fastener: Description and Operation Metric Wheel Nuts and Bolts Description Metric wheel/nuts and bolts are identified in the following way: ^ The wheel/nut has the word Metric stamped on the face. ^ The letter M is stamped on the end of the wheel bolt. The thread sizes of metric wheel/nuts and the bolts are indicated by the following example: M12 x 1.5. ^ M = Metric ^ 12 = Diameter in millimeters ^ 1.5 = Millimeters gap per thread Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension Wheel Fastener: Service and Repair Front Suspension Wheel Stud Replacement ^ Tools Required J 6627-A Tie Rod Puller Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper and bracket. Hang the caliper and the bracket from the vehicle. DO NOT allow the caliper and the bracket to hang by the brake hose. 4. Remove the brake rotor. 5. Use the J 6627-A in order to extract the stud (1) from the hub (2). Installation Procedure 1. Install a replacement stud in the wheel hub. 2. Add enough washers (3) in order to draw the stud into the hub (2). 3. Install the wheel nut (1) with the flat side against the washers (3). Important: Fully seat the wheel stud against the hub flange (2). 4. Tighten the wheel nut (1) until the wheel stud is fully seated against the hub flange. 5. Back off the wheel nut (1) and remove the washers (3). 6. Install the brake rotor. 7. Install the brake caliper and bracket. 8. Install the tire and wheel assembly. 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Service and Repair > Front Suspension > Page 7157 Wheel Fastener: Service and Repair Rear Suspension Wheel Stud Replacement ^ Tools Required J 6627-A Tie Rod Puller Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel assembly. 3. Remove the brake caliper and bracket. Hang the caliper and the bracket from the vehicle. DO NOT allow the caliper and the bracket to hang by the brake hose. 4. Remove the brake rotor. 5. Use the J 6627-A in order to extract the stud (1) from the hub (2). Installation Procedure 1. Install a replacement stud in the wheel hub. 2. Add enough washers (3) in order to draw the stud into the hub (2). 3. Install the wheel nut (1) with the flat side against the washers (3). Important: Fully seat the wheel stud against the hub flange (2). 4. Tighten the wheel nut (1) until the wheel stud is fully seated against the hub flange. 5. Back off the wheel nut (1) and remove the washers (3). 6. Install the brake rotor. 7. Install the brake caliper and bracket. 8. Install the tire and wheel assembly. 9. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 07-01-39-002B > Sep > 07 > A/C - Not Cold Enough/Poor Heat Output/DTC's Set Air Door Actuator / Motor: Customer Interest A/C - Not Cold Enough/Poor Heat Output/DTC's Set Bulletin No.: 07-01-39-002B Date: September 07, 2007 ENGINEERING INFORMATION Subject: EI07091 - A/C Not Cold Enough, HVAC Mode Doesn't Change, Heat Not Hot Enough, B0409, B0419, B0269, B0249, B0408, B0268, B0418, B0248, B0414, B3749, B0424, B3748 (Actuator Diagnosis) Models: 2004-2005 Chevrolet Impala, Monte Carlo Supercede: This bulletin is being revised to cancel the need for technician feedback and to provide corrective action. Please discard Corporate Bulletin Number 07-01-39-002A (Section 01 - HVAC). Condition Customers may comment about any of the following conditions: A/C not cold enough - A/C blows warm Heater not hot enough - heater blows cold Temp door does not move Correction Following the actuator diagnostic information found in SI (Service Information). Replace the actuator as necessary. Warranty Information Select the appropriate labor operation from the Labor Time Guide based on the repair made. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 04-01-38-009 > Jun > 04 > A/C - Not Cold Enough/DTCs B0268 & B0269 Set Air Door Actuator / Motor: Customer Interest A/C - Not Cold Enough/DTCs B0268 & B0269 Set Bulletin No.: 04-01-38-009 Date: June 30, 2004 TECHNICAL Subject: Poor A/C Performance - A/C Will Not Blow Cold Enough, Recirculation Mode Door Inoperative, DTCs B0268 and B0269 Set (Replace Recirculation (Air Inlet) Actuator) Models: 2004 Chevrolet Impala, Monte Carlo 2004 Pontiac Grand Prix Built Prior to September 2003 Condition Some customers may comment on less than desirable A/C performance, especially in hot ambient temperatures. Cause The cause of this condition may be the air recirculation door being stuck in the "outside air" mode. Diagnosis A quick test to determine if the air recirculation door is stuck in the "outside air" mode is to place a dollar bill or a piece of paper the size of a dollar bill on the outside air inlet grille. With the A/C on and in either Bi-Level or Vent mode, observe the paper. If the paper is sucked down and stays sucked down on the grille when the recirculation button is pressed, then the air recirculation door is stuck in the "outside air" mode. Correction Replace the recirculation (air inlet) actuator with P/N 10356910. Refer the Recirculation Actuator Replacement procedure in the HVAC System - Manual sub-section of the Service Manual. This new actuator motor contains grease to improve recirculation mode performance. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Actuator / Motor: > 04-01-38-009 > Jun > 04 > A/C - Not Cold Enough/DTCs B0268 & B0269 Set > Page 7172 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 07-01-39-002B > Sep > 07 > A/C - Not Cold Enough/Poor Heat Output/DTC's Set Air Door Actuator / Motor: All Technical Service Bulletins A/C - Not Cold Enough/Poor Heat Output/DTC's Set Bulletin No.: 07-01-39-002B Date: September 07, 2007 ENGINEERING INFORMATION Subject: EI07091 - A/C Not Cold Enough, HVAC Mode Doesn't Change, Heat Not Hot Enough, B0409, B0419, B0269, B0249, B0408, B0268, B0418, B0248, B0414, B3749, B0424, B3748 (Actuator Diagnosis) Models: 2004-2005 Chevrolet Impala, Monte Carlo Supercede: This bulletin is being revised to cancel the need for technician feedback and to provide corrective action. Please discard Corporate Bulletin Number 07-01-39-002A (Section 01 - HVAC). Condition Customers may comment about any of the following conditions: A/C not cold enough - A/C blows warm Heater not hot enough - heater blows cold Temp door does not move Correction Following the actuator diagnostic information found in SI (Service Information). Replace the actuator as necessary. Warranty Information Select the appropriate labor operation from the Labor Time Guide based on the repair made. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 04-01-38-009 > Jun > 04 > A/C - Not Cold Enough/DTCs B0268 & B0269 Set Air Door Actuator / Motor: All Technical Service Bulletins A/C - Not Cold Enough/DTCs B0268 & B0269 Set Bulletin No.: 04-01-38-009 Date: June 30, 2004 TECHNICAL Subject: Poor A/C Performance - A/C Will Not Blow Cold Enough, Recirculation Mode Door Inoperative, DTCs B0268 and B0269 Set (Replace Recirculation (Air Inlet) Actuator) Models: 2004 Chevrolet Impala, Monte Carlo 2004 Pontiac Grand Prix Built Prior to September 2003 Condition Some customers may comment on less than desirable A/C performance, especially in hot ambient temperatures. Cause The cause of this condition may be the air recirculation door being stuck in the "outside air" mode. Diagnosis A quick test to determine if the air recirculation door is stuck in the "outside air" mode is to place a dollar bill or a piece of paper the size of a dollar bill on the outside air inlet grille. With the A/C on and in either Bi-Level or Vent mode, observe the paper. If the paper is sucked down and stays sucked down on the grille when the recirculation button is pressed, then the air recirculation door is stuck in the "outside air" mode. Correction Replace the recirculation (air inlet) actuator with P/N 10356910. Refer the Recirculation Actuator Replacement procedure in the HVAC System - Manual sub-section of the Service Manual. This new actuator motor contains grease to improve recirculation mode performance. Parts Information Parts are currently available from GMSPO. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Actuator / Motor: > 04-01-38-009 > Jun > 04 > A/C - Not Cold Enough/DTCs B0268 & B0269 Set > Page 7182 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 7183 Air Door Actuator / Motor: Locations Lower Center Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 7184 Lower Right Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 7185 Air Door Actuator / Motor: Diagrams Air Temperature Actuator - Left Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 7186 Air Temperature Actuator - Right Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 7187 Mode Actuator Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 7188 Recirculation Actuator Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Technical Service Bulletins > Page 7189 Air Door Actuator / Motor: Description and Operation MODE/RECIRCULATION ACTUATOR The Buehler actuator is a 2 wire bi-directional electric motor. Two control circuits enable the actuator to operate. The control circuits use either a 0 or 12-volt value to co-ordinate the actuator movement. When the actuator is at rest, both control circuits have a value of 0 volts. In order to move the actuator, the HVAC control module grounds the appropriate control circuit for the commanded direction. The HVAC control module reverses the polarity of the control circuits to move the actuator in the opposite direction. The HVAC control module determines the door position by counting motor pulses on one of the control circuits. These pulses are small voltage fluctuations that occur when the brush is shorted across 2 commutator contacts as the motor rotates. As the actuator shaft rotates, the HVAC control module monitors the voltage drop across an internal resistance to detect the pulses. The HVAC control module converts the pulses to counts with a range of 0 to 255 counts. The HVAC control module uses a range of 0-255 counts to index the actuator position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator Replacement - Left Air Door Actuator / Motor: Service and Repair Air Temperature Actuator Replacement - Left AIR TEMPERATURE ACTUATOR REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left instrument panel (I/P) insulator. 2. Remove the knee bolster bracket bracket. 3. Disconnect the electrical connector from the left air temperature actuator. 4. Remove the mounting screws from the left air temperature actuator. 5. Remove the left air temperature actuator. INSTALLATION PROCEDURE 1. Position the left air temperature actuator. Align the slots in the electric actuator driver to the flats on the shaft. 2. Align the locating hole to the alignment pin on the HVAC module case. 3. Slide the actuator on the shaft. The actuator driver should seat completely onto the shaft and the mounting holes should be flush with the mounting screws on the HVAC module case. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the mounting screws to the left air temperature actuator. Tighten Tighten the screws to 1.5 N.m (13 lb in). 5. Connect the electrical connector to the left air temperature actuator. 6. Install the knee bolster bracket bracket. 7. Install the left I/P insulator. 8. Calibrate the actuator. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator Replacement - Left > Page 7192 Air Door Actuator / Motor: Service and Repair Air Temperature Actuator Replacement - Right AIR TEMPERATURE ACTUATOR REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the right side instrument panel (I/P) insulator. 2. Remove the I/P compartment. 3. Disconnect the electrical connector from the right air temperature actuator. 4. Remove the screws retaining the right air temperature actuator (2). 5. Remove the right air temperature actuator from the HVAC module assembly. INSTALLATION PROCEDURE 1. Position the right air temperature actuator (2). Align the slots in the electric actuator driver to the flats on the shaft. 2. Align the locating hole to the alignment pin on the HVAC module case. 3. Slide the actuator on the shaft. The actuator driver should seat completely onto the shaft and the mounting holes should be flush with the mounting screws on the HVAC module case. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the right air temperature actuator. Tighten Tighten the screws to 1.5 N.m (13 lb in). 5. Connect the electrical connector to the right air temperature actuator. 6. Install the I/P compartment. 7. Install the right side I/P insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator Replacement - Left > Page 7193 8. Calibrate the actuator. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator Replacement - Left > Page 7194 Air Door Actuator / Motor: Service and Repair Mode Actuator Replacement MODE ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the right instrument panel (I/P) insulator. 2. Remove the I/P compartment. 3. Disconnect the electrical connector from the mode actuator. 4. Remove the screws that secure the mode actuator (1) to the HVAC module assembly. 5. Remove the mode actuator from the HVAC module assembly. INSTALLATION PROCEDURE 1. Position the mode actuator, aligning the slots in the electric actuator drive to the flats on the shaft. 2. Align the locating hole to the alignment pin on the HVAC module assembly. 3. Slide the actuator drive completely onto the shaft, with the mounting holes flush with the mounting screw holes on the HVAC module assembly. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the mode actuator (1). Tighten Tighten the screws to 1.5 N.m (13 lb in). 5. Connect the electrical connector to the mode actuator. 6. Install the I/P compartment. 7. Install the right I/P insulator. 8. Calibrate the actuator. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Air Temperature Actuator Replacement - Left > Page 7195 Air Door Actuator / Motor: Service and Repair Recirculation Actuator Replacement RECIRCULATION ACTUATOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the right instrument panel (I/P) insulator. 2. Remove the I/P compartment. 3. Disconnect the electrical connector from the recirculation actuator. 4. Remove the screws that secure the recirculation actuator to the HVAC module assembly. 5. Remove the recirculation actuator from the HVAC module assembly. INSTALLATION PROCEDURE 1. Position the recirculation actuator, aligning the slots in the electric actuator drive to the flats on the shaft. 2. Align the locating hole to the alignment pin on the HVAC module assembly. 3. Slide the actuator drive completely onto the shaft, with the mounting holes flush with the mounting screw holes on the HVAC module assembly. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the recirculation actuator. Tighten Tighten the screws to 1.5 N.m (13 lb in). 5. Connect the electrical connector to the recirculation actuator. 6. Install the I/P compartment. 7. Install the right I/P insulator. 8. Calibrate the actuator. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair Air Duct: Service and Repair AIR DISTRIBUTION DUCT REPLACEMENT REMOVAL PROCEDURE 1. Remove the I/P lower trim panel. 2. Remove the retaining screw (1) from the air distribution duct. 3. Remove the retaining bolts from the air distribution duct. 4. Remove the air distribution duct from the cross vehicle beam. 5. Reposition the right I/P fuse junction block. 6. Remove the retaining bolts from the right air distribution duct. 7. Remove the right air distribution duct from the cross vehicle beam. INSTALLATION PROCEDURE 1. Install the right air distribution duct to the cross vehicle beam. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Page 7199 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the right air distribution duct bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Install the right I/P fuse junction block. 4. Install the air distribution duct to the cross vehicle beam. 5. Install the air distribution duct screw (1). Tighten Tighten the screw (1) to 1.5 N.m (13 lb in). 6. Install the air distribution duct bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 7. Install the I/P lower trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest for Air Register: > 06-01-39-010A > Jun > 08 > A/C - Horizontal Vent Louvers Loose or Inoperative Air Register: Customer Interest A/C - Horizontal Vent Louvers Loose or Inoperative TECHNICAL Bulletin No.: 06-01-39-010A Date: June 26, 2008 Subject: HVAC Horizontal Vent Louvers Loose or Inoperative (Reinstall Louver Tabs Into Thumbwheel/Deflector Housing) Models: 2000-2009 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-01-39-010 (Section 01 - HVAC). Condition Some customers may comment that when rotating the thumbwheel on the deflector vent, the horizontal vent louvers will not open or close properly. Cause This condition may be caused by the horizontal vent louver tabs becoming disengaged from the retaining holes in the thumbwheel actuator or the deflector housing. This causes the louvers to become inoperative or loose. The louvers are designed to move together in a uniform manner. Correction Shine a light into the deflector vent housing to determine if the inoperative louver still has two round tabs on one side and one round tab on the other side of the louver. If you are having difficulty seeing the tabs, it may be necessary to remove the inoperative louver. If the tabs are broken or the louver is missing, this bulletin does not apply. If all the round tabs are present, then proceed to reinstall the horizontal louver using the procedure below: Example of Deflector Vent with Louver Removed (Two Round Tabs on End of Louver Shown) Important: Depending on which louver you are working on, it may be necessary to have the louvers fully open but be careful not to drop the louver into the air duct. You may need a pair of needle-nose pliers to hold onto the louver when trying to position the two tabs into the thumbwheel and the housing pivot hole. 1. Start with the side thumbwheel in the down position and the horizontal louvers in the near closed position. 2. Install the two tabs of the louver into the thumbwheel actuator hole and the deflector housing pivot hole. 3. Bow the louver you are trying to reinstall outward towards you. 4. With the louver bowed, install the single tab into the opposite deflector housing pivot hole. 5. The louver may show a slight bow after installing. It may be necessary to straighten the louver by slightly bending the louver in the opposite position of the bow. 6. Verify the proper operation of the vent deflector louvers by using the thumbwheel control. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > Customer Interest for Air Register: > 06-01-39-010A > Jun > 08 > A/C - Horizontal Vent Louvers Loose or Inoperative > Page 7208 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Register: > 06-01-39-010A > Jun > 08 > A/C - Horizontal Vent Louvers Loose or Inoperative Air Register: All Technical Service Bulletins A/C - Horizontal Vent Louvers Loose or Inoperative TECHNICAL Bulletin No.: 06-01-39-010A Date: June 26, 2008 Subject: HVAC Horizontal Vent Louvers Loose or Inoperative (Reinstall Louver Tabs Into Thumbwheel/Deflector Housing) Models: 2000-2009 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 06-01-39-010 (Section 01 - HVAC). Condition Some customers may comment that when rotating the thumbwheel on the deflector vent, the horizontal vent louvers will not open or close properly. Cause This condition may be caused by the horizontal vent louver tabs becoming disengaged from the retaining holes in the thumbwheel actuator or the deflector housing. This causes the louvers to become inoperative or loose. The louvers are designed to move together in a uniform manner. Correction Shine a light into the deflector vent housing to determine if the inoperative louver still has two round tabs on one side and one round tab on the other side of the louver. If you are having difficulty seeing the tabs, it may be necessary to remove the inoperative louver. If the tabs are broken or the louver is missing, this bulletin does not apply. If all the round tabs are present, then proceed to reinstall the horizontal louver using the procedure below: Example of Deflector Vent with Louver Removed (Two Round Tabs on End of Louver Shown) Important: Depending on which louver you are working on, it may be necessary to have the louvers fully open but be careful not to drop the louver into the air duct. You may need a pair of needle-nose pliers to hold onto the louver when trying to position the two tabs into the thumbwheel and the housing pivot hole. 1. Start with the side thumbwheel in the down position and the horizontal louvers in the near closed position. 2. Install the two tabs of the louver into the thumbwheel actuator hole and the deflector housing pivot hole. 3. Bow the louver you are trying to reinstall outward towards you. 4. With the louver bowed, install the single tab into the opposite deflector housing pivot hole. 5. The louver may show a slight bow after installing. It may be necessary to straighten the louver by slightly bending the louver in the opposite position of the bow. 6. Verify the proper operation of the vent deflector louvers by using the thumbwheel control. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Register: > 06-01-39-010A > Jun > 08 > A/C - Horizontal Vent Louvers Loose or Inoperative > Page 7214 Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Defroster Air Register: Service and Repair Air Outlet Replacement - Defroster AIR OUTLET REPLACEMENT - DEFROSTER REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. Remove the I/P lower trim panel. 3. Remove the retaining screw (1) from the panel air duct. 4. Remove the retaining bolts from the panel air duct. 5. Remove the panel air duct from the cross vehicle beam. 6. Remove the bolts from the left side fuse block to cross vehicle beam. 7. Disconnect the left side fuse block wire harness from the cross vehicle beam. 8. Position the left side fuse block aside. 9. Disconnect the wire harness connectors from the body control module. 10. Disconnect the body control module from the cross vehicle beam. 11. Remove the body control module from the vehicle. 12. Remove the bolts from the right side fuse block to cross vehicle beam. 13. Disconnect the right side fuse block wire harness from the cross vehicle beam. 14. Position the right side fuse block aside. 15. Remove the brake pedal. 16. Remove the 3 brake pedal brace bolts from the cross vehicle beam. 17. Disconnect any ground wires, as necessary. 18. Disconnect the electrical connector from the HVAC module assembly to main wire harness connector. 19. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness aside. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Defroster > Page 7217 20. Remove the bolts from the HVAC module upper support. 21. Remove the bolt (1) from the left side of the HVAC module assembly lower support. 22. Remove the bolt (2) from the right side of the HVAC module assembly lower support. 23. Remove the bolts from the right and left side of the cross vehicle beam. 24. Remove the cross vehicle beam. 25. Remove the defroster air duct retaining bolts. 26. Remove the defroster air duct from the cross vehicle beam. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Defroster > Page 7218 1. Install the defroster air duct to the cross vehicle beam. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the defroster air duct bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Install the cross vehicle beam to the vehicle. 4. Install the bolts to the right and left side of the cross vehicle beam. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Defroster > Page 7219 5. Tighten the bolts to the right and left side of the cross vehicle beam in sequence. Tighten Tighten the bolts to 25 N.m (18 lb ft). 6. Install the bolts to the HVAC module upper support. Tighten Tighten the bolts to 4 N.m (35 lb in). 7. Install the bolt (1) to the left side of the HVAC module assembly lower support. Tighten Tighten the bolt to 4 N.m (35 lb in). 8. Install the bolt (2) to the right side of the HVAC module assembly lower support. Tighten Tighten the bolt to 4 N.m (35 lb in). 9. Reposition the I/P wiring harness on to the cross vehicle beam and secure the retaining clips. 10. Connect all disconnected ground wires. 11. Connect the electrical connector from the HVAC module assembly to main harness connector. 12. Install the three brake pedal brace bolts. Tighten Tighten the bolts to 50 N.m (37 lb ft). 13. Install the brake pedal. 14. Install the body control module to the cross vehicle beam. 15. Connect the wire harness connectors to the body control module. 16. Install the left side fuse block to the cross vehicle beam. 17. Install the bolts to the left side fuse block. Tighten Tighten the bolts to 10 N.m (89 in lb). 18. Install the right side fuse block to the cross vehicle beam. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Defroster > Page 7220 19. Install the bolt to the right side fuse block. Tighten Tighten the bolt to 10 N.m (89 in lb). 20. Install the panel air duct to the cross vehicle beam. 21. Install the panel air duct screw (1). Tighten Tighten the screw to 1.8 N.m (16 lb in). 22. Install the panel air duct bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 23. Install the I/P lower trim panel. 24. Connect the battery negative cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Defroster > Page 7221 Air Register: Service and Repair Air Outlet Replacement - Rear Floor AIR OUTLET REPLACEMENT - REAR FLOOR REMOVAL PROCEDURE 1. Remove the floor carpet. 2. Remove the rear floor air outlet duct (1) from the holes in the floor reinforcement. 3. Disconnect the rear floor air outlet duct from the heater outlet cover. 4. Remove the rear floor air outlet duct. INSTALLATION PROCEDURE 1. Install the rear floor air outlet duct. 2. Connect the rear floor air outlet duct to the heater outlet cover. 3. Position the rear floor air outlet duct (1) into the holes in the floor reinforcement. 4. Install the floor carpet. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Air Register > Component Information > Service and Repair > Air Outlet Replacement - Defroster > Page 7222 Air Register: Service and Repair Air Outlet Replacement - Side Window AIR OUTLET REPLACEMENT - SIDE WINDOW REMOVAL PROCEDURE 1. Remove the I/P upper trim pad. 2. If required, remove the air outlet screw. Monte Carlo shown, Impala similar. 3. Disengage the air outlet retainers. Remove the air outlet. INSTALLATION PROCEDURE 1. Install the air outlet to the I/P upper trim pad and engage the air outlet retainers. NOTE: Refer to Fastener Notice in Service Precautions. 2. If required, install the air outlet screw. Monte Carlo shown, Impala similar. Tighten Tighten the screw to 2 N.m (18 lb in). 3. Install the I/P upper trim pad. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Front Of Vehicle Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7226 Ambient Air Temperature Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7227 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE GAGE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector from the ambient temperature sensor that is located on the front radiator air baffle. 3. Remove the ambient temperature sensor from the radiator air baffle. INSTALLATION PROCEDURE 1. Install the ambient temperature sensor to the radiator air baffle. 2. Connect the electrical connector to the ambient temperature sensor. 3. Lower the vehicle. 4. Drive the vehicle at a speed of 32 km/h (20 mph) for approximately 1 1/2 minutes or at a speed of 72 km/h (45 mph) for approximately 1 minute in order to obtain the ambient update. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions Auxiliary Blower Motor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7233 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7234 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7235 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7236 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7237 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7238 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7239 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7240 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7241 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7242 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7243 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7244 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7245 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7246 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7247 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7248 Auxiliary Blower Motor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7249 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7250 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7251 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7252 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7253 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7254 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7255 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7256 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7257 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7258 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7259 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7260 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7261 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7262 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7263 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7264 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7265 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7266 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7267 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7268 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7269 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7270 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7271 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7272 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7273 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7274 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Blower Motor > Auxiliary Blower Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7275 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations Cabin Air Filter: Locations PASSENGER COMPARTMENT AIR FILTER The Passenger Compartment Air Filter is located underneath the hood just below the windshield wiper arm on the passenger's side of the vehicle, underneath the air inlet grille. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations > Page 7279 Cabin Air Filter: Service and Repair PASSENGER COMPARTMENT AIR FILTER REPLACEMENT REMOVAL PROCEDURE 1. Position the windshield wipers in the UP position, by keying the ignition OFF when the wiper reach the desired position. 2. Raise the hood. 3. Remove the rear hood seal. 4. Remove the washer hose from the right air inlet grill panel and position aside. 5. Remove the two push pin retainers from the right air inlet grill panel. IMPORTANT: Do not remove the third push pin retainer from the right air inlet grill panel 6. Position the left side of the right air inlet grill panel on to the windshield. 7. Remove the passenger compartment air filter. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Air Filter > Component Information > Locations > Page 7280 1. Install the passenger compartment air filter. 2. Install the left side of the right air inlet grill panel in to position. 3. Install the push pin retainers to the right air inlet grill panel. 4. Position the washer hose in to the right air inlet grill panel clips. 5. Install the rear hood seal. 6. Close the hood. 7. Return the windshield wipers to the PARK position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Duct > Component Information > Service and Repair Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Open the rear compartment. 2. Remove the rear bumper fascia. 3. Pull back the rear compartment trim panel. 4. Apply pressure at 2 upper locations and 2 lower locations, using a small, flat-bladed tool in order to release the retainers on the pressure relief valve. 5. Remove the pressure relief valve from the lower quarter panel. Installation Procedure 1. Install the pressure relief valve to the lower quarter panel. 2. Press the pressure relief valve into the quarter lower panel until the retainers lock into place at the upper and lower locations. 3. Pull back the rear compartment trim panel. 4. Install the rear bumper fascia. 5. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Open the rear compartment. 2. Remove the rear bumper fascia. 3. Pull back the rear compartment trim panel. 4. Apply pressure at 2 upper locations and 2 lower locations, using a small, flat-bladed tool in order to release the retainers on the pressure relief valve. 5. Remove the pressure relief valve from the lower quarter panel. Installation Procedure 1. Install the pressure relief valve to the lower quarter panel. 2. Press the pressure relief valve into the quarter lower panel until the retainers lock into place at the upper and lower locations. 3. Pull back the rear compartment trim panel. 4. Install the rear bumper fascia. 5. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams A/C Compressor Clutch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 7291 Compressor Clutch: Service and Repair COMPRESSOR CLUTCH ASSEMBLY REPLACEMENT TOOLS REQUIRED - J 37872 Compressor Clutch Holding Tool - J 6083 Snap Ring Pliers REMOVAL PROCEDURE 1. Remove the compressor. IMPORTANT: Remove the three adjustable dowels from the J37872 Compressor Clutch Holding Tool. Install three 5/16 x 1 inch bolts in place of the dowels. 2. Remove and discard the compressor clutch plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 7292 3. Remove the compressor clutch plate from the compressor. 4. Remove the compressor pulley snap ring using the J 6083. 5. Remove the compressor pulley from the compressor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 7293 6. Remove the compressor clutch coil snap ring using the J 6083. 7. Remove the compressor clutch coil from the compressor. INSTALLATION PROCEDURE 1. Carefully clean the clutch plate bolt threads with a M6x1.0 tap. Carefully blow out debris with compressed air. 2. Install the compressor clutch coil to the compressor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 7294 3. Install the compressor clutch coil snap ring using the J 6083. 4. Install the compressor pulley to the compressor. 5. Install the compressor pulley snap ring using the J 6083. 6. Place a small amount of oil on the 0.4 mm (0.016 in) air gap shim and place inside the clutch drive plate. 7. Install the compressor clutch plate to the compressor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Diagrams > Page 7295 IMPORTANT: Make certain that the drive plate does not drag against the pulley when the pulley is rotated. 8. Measure the air gap between the pulley and the drive plate. Adjust the shims to achieve a 0.3-0.6 mm (0.012-0.024 in) air gap. NOTE: Refer to Fastener Notice in Service Precautions. IMPORTANT: Make certain that the new drive plate bolt has colored adhesive on at least 5 threads. 9. Install the clutch drive plate bolt. 10. Tighten the compressor clutch drive plate bolt. Use the J 37872 to hold the compressor clutch plate from turning. Tighten Tighten the bolt to 12 N.m (106 lb in). 11. Install the compressor. 12. Leak test the fittings using the J 39400-A. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Remove the underhood lower relay cover. 3. Remove the A/C compressor control relay from the electrical center. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Service and Repair > Page 7299 1. Install the A/C compressor control relay into the electrical center. 2. Install the underhood lower relay cover. 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair Condenser HVAC: Service and Repair CONDENSER REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the radiator. 3. Remove the A/C line coupling from the condenser tube to the receiver dehydrator tube. 4. Remove the A/C compressor line nut from the condenser and position the A/C compressor line aside. 5. Remove the condenser from the vehicle. 6. Remove and discard the O-ring seals and seal washer. INSTALLATION PROCEDURE 1. If replacing the condenser, add refrigerant oil to the condenser. Refer to Refrigerant System Capacities for system capacity information. 2. Install the condenser to the vehicle. 3. Install a new seal washer onto the A/C compressor hose. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and Repair > Page 7303 4. Install new O-ring seals onto the receiver dehydrator tube. 5. Install the receiver dehydrator tube to the condenser. 6. Install the A/C line coupling to the receiver dehydrator tube and the condenser tube. 7. Install the A/C compressor hose to the condenser. Install the A/C compressor hose block fitting nut to the condenser. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nut to 16 N.m (12 lb ft). 8. Install the radiator. 9. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 10. Leak test the fittings of the component using J 39400-A. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > A/C - Control Knob Replacement Availability Control Assembly: Technical Service Bulletins A/C - Control Knob Replacement Availability Bulletin No.: 04-01-37-001 Date: January 06, 2004 INFORMATION Subject: HVAC Control Knob Replacement Models: 2000-2004 All Passenger Cars and Light Duty Trucks 2003-04 HUMMER H2 HVAC Control Knob Availability Important: If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. The various knobs used on the HVAC controls of most GM vehicles are available for purchase separately from the HVAC head units. If a knob becomes loose or broken, you MUST first check for availability of the control knob before attempting to replace the entire HVAC controller. Please use only the labor operation code listed below when replacing an HVAC control knob. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 7308 Control Assembly: Service and Repair HVAC CONTROL ASSEMBLY REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel trim plate bezel. 2. Remove the retaining screws from the HVAC control module. 3. Pull the HVAC control module out from the instrument panel. 4. Disconnect the electrical connectors from the HVAC control module. 5. Remove the HVAC control module from the instrument panel. INSTALLATION PROCEDURE IMPORTANT: The key should be in the off position when connecting the electrical connectors to ensure proper calibration. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Technical Service Bulletins > Page 7309 1. Connect the electrical connectors to the HVAC control module. 2. Install the HVAC control module into the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retaining screws to secure the HVAC control module. Tighten Tighten the screws to 1.8 N.m (16 lb in). 4. Install the instrument panel trim plate bezel. IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC control module is calibrating. If interrupted improper HVAC performance will result. 5. Start the engine and run for one minute. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations Middle Center Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Page 7313 Control Module HVAC: Diagrams HVAC Control Module Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Page 7314 HVAC Control Module Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Page 7315 HVAC Control Module Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Page 7316 Control Module HVAC: Description and Operation HVAC CONTROL MODULE The HVAC control module is a Class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The control module supports the following features: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Locations > Page 7317 Control Module HVAC: Service and Repair BLOWER CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the right side instrument panel insulator. 2. Disconnect the electrical connector from the blower control module. 3. Remove the two heat stakes from the blower control module using a small chisel. 4. Remove the blower control module. INSTALLATION PROCEDURE 1. Install the blower control module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the two new screws in the pre drilled holes to the side of the heat stakes in the blower control module and HVAC module assembly. Tighten Tighten the screws to 1.5 N.m (13 lb in). 3. Connect the electrical connector to the blower control module. 4. Install the right side instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement A/C Coupler O-ring: Service and Repair O-Ring Replacement O-RING REPLACEMENT REMOVAL PROCEDURE 1. Disassemble the A/C refrigerant components. Refer to the appropriate repair procedure. 2. Remove the O-ring seals from the A/C refrigerant component. 3. Inspect the O-ring seals for signs of damage. 4. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 5. Cap or tape the A/C refrigerant components. 6. Discard the O-ring seals. INSTALLATION PROCEDURE 1. Inspect the new O-ring seals for any sign or cracks, cuts, or damage. Replace if necessary. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the A/C refrigerant components. IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the new O-ring seal to enter the refrigerant system. 4. Lightly coat the new O-ring seals with mineral base 525 viscosity refrigerant oil. IMPORTANT: DO NOT reuse O-ring seals. 5. Carefully slide the new O-ring seals onto the A/C refrigerant component. 6. The O-ring seals must be fully seated. 7. Assemble the A/C components. Refer to the appropriate repair procedure. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Service and Repair > O-Ring Replacement > Page 7323 A/C Coupler O-ring: Service and Repair Sealing Washer Replacement SEALING WASHER REPLACEMENT REMOVAL PROCEDURE 1. Remove the seal washer from the A/C refrigerant component. IMPORTANT: Cap or tape the open A/C refrigerant components immediately to prevent system contamination. 2. Inspect the seal washer for signs of damage to help determine the root cause of the failure. 3. Inspect the A/C refrigerant components for damage or burrs. Repair if necessary. IMPORTANT: DO NOT reuse sealing washer. 4. Discard the sealing washer. INSTALLATION PROCEDURE IMPORTANT: Flat washer type seals do not require lubrication. 1. Inspect the new seal washer for any signs of cracks, cuts, or damage. Do not use a damaged seal washer. 2. Remove the cap or tape from the A/C refrigerant components. 3. Using a lint-free clean, dry cloth, clean the sealing surfaces of the A/C refrigerant components. 4. Carefully install the new seal washer onto the A/C refrigerant component. The washer must completely bottom against the surface of the fitting. IMPORTANT: After tightening the A/C components, there should be a slight sealing washer gap of approximately 1.2 mm (3/64 in) between the A/C line and the A/C component. 5. Assemble the remaining A/C refrigerant components. Refer to the appropriate repair procedure. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: Customer Interest A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 7332 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 7333 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System Evaporator Core: All Technical Service Bulletins A/C - Musty Odors Emitted From (HVAC) System TECHNICAL Bulletin No.: 99-01-39-004C Date: June 12, 2009 Subject: Air Conditioning Odor (Install Evaporator Core Dryer Kit and Apply Cooling Coil Coating) Models: 1993-2010 GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 All Equipped with Air Conditioning Supercede: This bulletin is being revised to add the 2009 and 2010 model years. Please discard Corporate Bulletin Number 99-01-39-004B (Section 01 - HVAC). Condition Some customers may comment about musty odors emitted from the Heating, Ventilation and Air Conditioning (HVAC) system at vehicle start-up in hot, humid conditions. Cause This condition may be caused by condensate build-up on the evaporator core, which does not evaporate by itself in high humidity conditions. The odor may be the result of microbial growth on the evaporator core. When the blower motor fan is turned on, the microbial growth may release an unpleasant musty odor into the passenger compartment. There are several other possible sources of a musty odor in a vehicle. A common source is a water leak into the interior of the vehicle or foreign material in the HVAC air distribution system. Follow the procedures in SI for identifying and correcting water leaks and air inlet inspection. The procedure contained in this bulletin is only applicable if the odor source has been determined to be microbial growth on the evaporator core inside the HVAC module. Correction Many vehicles currently incorporate an afterblow function within the HVAC control module software. The afterblow feature, when enabled, employs the HVAC blower fan to dry the evaporator after vehicle shut down and this function will inhibit microbial growth. Technicians are to confirm that the customer concern is evaporator core odor and that the vehicle has the imbedded afterblow feature, as defined in the SI document for that specific vehicle model, model year and specific HVAC option. Refer to SI for enabling the afterblow function. Vehicles being delivered in areas prone to high humidity conditions may benefit from having the afterblow enabled calibration installed prior to any customer comment. Important If the vehicle is not factory equipped with the imbedded afterblow enable feature, it may be added with the Electronic Evaporator Dryer Module Kit (P/N 12497910 or AC Delco 15-5876). Important When installing the Electronic Evaporator Dryer Module, you MUST use the included electrical splice connectors to ensure a proper splice. Complete detailed installation instructions and self testing procedures are supplied with the kit. If necessary, the Electronic Evaporator Dryer Module may be installed underhood if it is protected from extreme heat and water splash areas. To immediately remove the evaporator core odor on all suspect vehicles, it is necessary to eliminate the microbial growth and prevent its re-occurrence. To accomplish this, perform the following procedure: Vehicle and Applicator Tool Preparation 1. The evaporator core must be dry. This may be accomplished by disabling the compressor and running the blower fan on the recirc heat setting for an extended period of time. Note Compressor engagement will cause the evaporator core to remain wet and will prevent full adherence of the Coiling Coil Coating to the evaporator core surfaces. 2. Verify that the air conditioning drain hose is not clogged and place a drain pan beneath the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 7339 3. Place a protective cover over the carpet below the evaporator core. 4. Remove the cabin air filter, if equipped, and cover the opening prior to applying the Cooling Coil Coating, as the product may clog the filter. If the cabin air filter appears to have little or no remaining life, suggest a replacement to your customer. 5. If the HVAC module has a blower motor cooling tube, be careful NOT TO SPRAY THE COOLING COIL COATING INTO THE BLOWER MOTOR COOLING TUBE. 6. Attach the Flexible Applicator Pressure Spray Tool (J-43810-20A) to a compressed air line operating at 586 kPa (85 psi) to 793 kPa (115 psi). 7. Shake the bottle of Cooling Coil Coating well. Screw the bottle onto the cap on the applicator tool's pick-up tube. Note The pick-up tube is designed for 120 ml (4 oz) and 240 ml (8 oz) bottles and should coil slightly in the bottom of a 120 ml (4 oz) bottle. 8. Use one of the following three methods to apply the Cooling Coil Coating. Important If the Pressure Applicator Spray Tool (J-43810-20A) is not available, the Cooling Coil Coating is also available in an aerosol can (P/N 12377951 (in Canada, 10953503)). Application Through Blower Motor Control Module Opening - Remove the blower motor control module (blower motor resistor). Refer to the applicable procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor blower motor control module (blower motor resistor) opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor blower motor control module (blower motor control module). Application Through Blower Motor Opening - Remove the blower motor. Refer to the applicable blower motor removal procedure in SI. - Clean any debris or foreign material from inside the HVAC module and on the evaporator core surface. - Apply the Cooling Coil Coating directly to the evaporator core through the blower motor opening. - Use the flexible wand to direct the Cooling Coil Coating over the entire evaporator core and surrounding gasket surfaces. - When the application is complete, install the blower motor. Application Through a Hole in the HVAC Module - If neither of the two previous application methods are available, it may be necessary to drill a hole in the HVAC module. - Locate an area of the HVAC module between the blower motor and the evaporator core. Drill a 10 mm (3/8 in) hole in the HVAC module. Use caution to keep the drill clear of the evaporator core and the blower motor fan. - With the air distribution vents closed and the blower motor fan speed on HIGH, insert the applicator tool into the hole and spray the Cooling Coil Coating into the airstream toward the evaporator core. - Use a GM approved RTV sealant to plug the hole in the HVAC module. 9. After the Cooling Coil Coating application is complete, start and run the vehicle for approximately 10 minutes, with the compressor disabled, HVAC mode set to Recirculate/Max, heat set to full warm, blower motor fan speed on high, and one window open approximately 12 mm (1/2 in). This cures the Cooling Coil Coating onto the evaporator core surface. 10. While the engine is running, rinse the applicator tool with warm water to prolong the life of the tool. Be sure to spray warm water through the nozzle to rinse out any residual Cooling Coil Coating still in the capillary pick up tube, otherwise it will dry and clog the applicator tool. Also remove the small green valve from the bottle cap and rinse it thoroughly while rolling it between two fingers and then reinstall it. If this valve is clogged , the Cooling Coil Coating will not flow through the applicator tool. 11. Shut off the engine and enable the compressor again. 12. Verify proper HVAC system operation. 13. Remove the protective cover from inside the vehicle. 14. Remove the drain pan from underneath the vehicle. 15. Reinstall the cabin air filter if necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 99-01-39-004C > Jun > 09 > A/C - Musty Odors Emitted From (HVAC) System > Page 7340 Parts Information Important The Cooling Coil Coating listed below is the only GM approved product for use under warranty as an evaporator core disinfectant and for the long term control of evaporator core microbial growth. Warranty Information For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 7341 Evaporator Core: Service and Repair EVAPORATOR CORE REPLACEMENT REMOVAL PROCEDURE 1. Remove the HVAC module assembly. See: Housing Assembly HVAC/Service and Repair 2. Disconnect the recirculation actuator electrical connector from the recirculation actuator. 3. Remove the recirculation actuator electrical harness from the recirculation housing clips. 4. Remove the screws that secure the recirculation housing to the HVAC module assembly. 5. Remove the recirculation housing from the HVAC module assembly. 6. Disconnect the mode actuator electrical connector from the mode actuator. 7. Remove the screws that secure the mode actuator to the HVAC module assembly. 8. Remove the mode actuator from the HVAC module assembly. 9. Disconnect the air temperature actuators electrical connector from the air temperature actuators. 10. Remove the bolts that secure the TXV to the evaporator core. 11. Remove the TXV from the evaporator core. 12. Discard the old seal washers from the evaporator core. 13. Remove the screws that secure HVAC module assembly upper case to the HVAC module assembly lower case. 14. Remove the heat stakes that secure the HVAC module assembly upper case to the HVAC module lower case using a small chisel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 7342 15. Separate the HVAC module assembly case (1). 16. Remove the evaporator core. INSTALLATION PROCEDURE 1. If replacing the evaporator, add refrigerant oil to the evaporator. Refer to Refrigerant System Capacities for system capacity information. 2. Install a new side seal to the evaporator core. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 7343 3. Install a new upper seal to the evaporator core. 4. Install 2 new lower seals to the evaporator core. 5. Install the evaporator core into the HVAC module assembly lower case. 6. From the inside of the upper case, drill the dimples adjacent to the heat stakes using a 5.5 mm (7/32 in) drill bit. 7. Align and attach the upper and lower HVAC module assembly case. NOTE: Refer to Fastener Notice in Service Precautions. 8. Install the removed screws that secure the HVAC module assembly upper case to the HVAC module assembly lower case to their original position. Tighten Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 7344 Tighten the screws to 1.5 N.m (13 lb in). 9. Install new screws that will secure the HVAC module assembly upper case to the HVAC module assembly lower case in the locations adjacent to the heat stakes that were removed. Tighten Tighten the screws to 1.5 N.m (13 lb in). 10. Connect the air temperature electrical connector the air temperature actuator. 11. Install the mode actuator. 12. Install the screws that secure the mode actuator to the HVAC module assembly. Tighten Tighten the screws to 15 N.m (13 lb in). 13. Connect the mode actuator electrical connector to the mode actuator. 14. Install the recirculation housing to the HVAC module assembly. 15. Install the screws that secure the recirculation housing to the HVAC module assembly. Tighten Tighten the screws to 1.5 N.m (13 lb in). 16. Route the recirculation actuator harness through the recirculation housing clips. 17. Connect the recirculation actuator electrical connector to the recirculation actuator. 18. Install new sealing washers on the evaporator core. 19. Install the TXV to the evaporator core. 20. Install the bolts that secure the TXV to evaporator core. Tighten Tighten the bolts to 7 N.m (62 lb in). 21. Install the HVAC module assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair Expansion Valve: Service and Repair THERMAL EXPANSION VALVE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Remove the evaporator tube to TXV nut (1). 3. Disconnect the evaporator outlet and inlet tube from the TXV. 4. Remove and discard the sealing washers. IMPORTANT: Cap or tape the open evaporator inlet and outlet tubes immediately to prevent contamination of the refrigerant system. 5. Cap off the evaporator inlet and outlet tube. 6. Remove the TXV to evaporator bolts. 7. Remove the TXV from the evaporator core. 8. Remove and discard the sealing washers. INSTALLATION PROCEDURE 1. Install the new sealing washers onto the evaporator core. 2. Install the TXV to the evaporator core. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and Repair > Page 7348 3. Install the TXV to evaporator bolts. Tighten Tighten the bolts to 7 N.m (62 lb in). 4. Remove the cap or tape from the evaporator inlet and outlet tubes. 5. Install the new sealing washers onto the evaporator inlet and outlet tubes. 6. Install the evaporator outlet and inlet tube to the TXV. 7. Install the evaporator tube nut (1). Tighten Tighten the nut to 27 N.m (20 lb ft). 8. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 9. Leak test the fittings of the component using J 39400-A. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators Heater Core: Technical Service Bulletins Cooling System, A/C - Aluminum Heater Cores/Radiators INFORMATION Bulletin No.: 05-06-02-001A Date: July 16, 2008 Subject: Information On Aluminum Heater Core and/or Radiator Replacement Models: 2005 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2005 HUMMER H2 Supercede: This bulletin is being revised to update the Warranty Information. Please discard Corporate Bulletin Number 05-06-02-001 (Section 06 - Engine/Propulsion System). Important: 2004-05 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX-COOL(R). Refer to the flushing procedure explained later in this bulletin. The following information should be utilized when servicing aluminum heater core and/or radiators on repeat visits. A replacement may be necessary because erosion, corrosion, or insufficient inhibitor levels may cause damage to the heater core, radiator or water pump. A coolant check should be performed whenever a heater core, radiator, or water pump is replaced. The following procedures/ inspections should be done to verify proper coolant effectiveness. Caution: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding fluid and steam under pressure if the radiator cap or surge tank cap is removed while the engine and radiator are still hot. Important: If the vehicle's coolant is low, drained out, or the customer has repeatedly added coolant or water to the system, then the system should be completely flushed using the procedure explained later in this bulletin. Technician Diagnosis ^ Verify coolant concentration. A 50% coolant/water solution ensures proper freeze and corrosion protection. Inhibitor levels cannot be easily measured in the field, but can be indirectly done by the measurement of coolant concentration. This must be done by using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale), or equivalent, coolant tester. The Refractometer uses a minimal amount of coolant that can be taken from the coolant recovery reservoir, radiator or the engine block. Inexpensive gravity float testers (floating balls) will not completely analyze the coolant concentration fully and should not be used. The concentration levels should be between 50% and 65% coolant concentrate. This mixture will have a freeze point protection of -34 degrees Fahrenheit (-37 degrees Celsius). If the concentration is below 50%, the cooling system must be flushed. ^ Inspect the coolant flow restrictor if the vehicle is equipped with one. Refer to Service Information (SI) and/or the appropriate Service Manual for component location and condition for operation. ^ Verify that no electrolysis is present in the cooling system. This electrolysis test can be performed before or after the system has been repaired. Use a digital voltmeter set to 12 volts. Attach one test lead to the negative battery post and insert the other test lead into the radiator coolant, making sure the lead does not touch the filler neck or core. Any voltage reading over 0.3 volts indicates that stray current is finding its way into the coolant. Electrolysis is often an intermittent condition that occurs when a device or accessory that is mounted to the radiator is energized. This type of current could be caused from a poorly grounded cooling fan or some other accessory and can be verified by watching the volt meter and turning on and off various accessories or engage the starter motor. Before using one of the following flush procedures, the coolant recovery reservoir must be removed, drained, cleaned and reinstalled before refilling the system. Notice: ^ Using coolant other than DEX‐COOL(R) may cause premature engine, heater core or radiator corrosion. In addition, the engine coolant may require changing sooner, at 30,000 miles (50,000 km) or 24 months, whichever occurs first. Any repairs would not be covered by your warranty. Always use DEX‐COOL(R) (silicate free) coolant in your vehicle. ^ If you use an improper coolant mixture, your engine could overheat and be badly damaged. The repair cost would not be covered by your warranty. Too much water in the mixture can freeze and crack the engine, radiator, heater core and other parts. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 7353 Flushing Procedures using DEX-COOL(R) Important: The following procedure recommends refilling the system with DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. This coolant is orange in color and has a service interval of 5 years or 240,000 km (150,000 mi). However, when used on vehicles built prior to the introduction of DEX-COOL(R), maintenance intervals will remain the same as specified in the Owner's Manual. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling system flush and fill machine is not available, drain the coolant and dispose of properly following the draining procedures in the appropriate Service Manual. Refill the system using clear, drinkable water and run the vehicle until the thermostat opens. Repeat and run the vehicle three (3) times to totally remove the old coolant or until the drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with DEX‐COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% DEX-COOL(R), P/N 12346290 (in Canada, use P/N 10953464), GM specification 6277M. Then slowly add clear, drinkable water (preferably distilled) to the system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and reverify the coolant level. If necessary, add clean water to restore the coolant to the appropriate level. Once the system is refilled, reverify the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. The concentration levels should be between 50% and 65%. Flushing Procedures using Conventional Silicated (Green Colored) Coolant Important: 2004-2005 Chevrolet Aveo (Pontiac Wave, Canada Only) does not use DEX‐COOL(R). The Aveo and Wave are filled with conventional, silicated engine coolant that is blue in color. Silicated coolants are typically green in color and are required to be drained, flushed and refilled every 30,000 miles (48,000 km). The Aveo and Wave are to be serviced with conventional, silicated coolant. Use P/N 12378560 (1 gal) (in Canada, use P/N 88862159 (1 L). Refer to the Owner's Manual or Service Information (SI) for further information on OEM coolant. Important: Do not mix the OEM orange colored DEX-COOL(R) coolant with green colored coolant when adding coolant to the system or when servicing the vehicle's cooling system. Mixing the orange and green colored coolants will produce a brown coolant which may be a customer dissatisfier and will not extend the service interval to that of DEX-COOL(R). Conventional silicated coolants offered by GM Service and Parts Operations are green in color. ^ If available, use the approved cooling system flush and fill machine (available through the GM Dealer Equipment Program) following the manufacturer's operating instructions. ^ If approved cooling systems flush and fill machine is not available, drain coolant and dispose of properly following the draining procedures in appropriate Service Manual. Refill the system using clear, drinkable water and run vehicle until thermostat opens. Repeat and run vehicle three (3) times to totally remove old coolant or until drained coolant is almost clear. Once the system is completely flushed, refill the cooling system to a 50%-60% concentration with a good quality ethylene glycol base engine coolant, P/N 12378560, 1 gal (in Canada, use P/N 88862159 1 L), conforming to GM specification 1825M, or recycled coolant conforming to GM specification 1825M, following the refill procedures in the appropriate Service Manual. If a Service Manual is not available, fill half the capacity of the system with 100% good quality ethylene glycol base (green colored) engine coolant, P/N 12378560 1 gal., (in Canada, use P/N 88862159 1 L) conforming to GM specification 1825M. Then slowly add clear, drinkable water (preferably distilled) to system until the level of the coolant mixture has reached the base of the radiator neck. Wait two (2) minutes and recheck coolant level. If necessary, add clean water to restore coolant to the appropriate level. Once the system is refilled, recheck the coolant concentration using a Refractometer J 23688 (Fahrenheit scale) or J 26568 (centigrade scale) coolant tester, or equivalent. Concentration levels should be between 50% and 65%. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Cooling System, A/C - Aluminum Heater Cores/Radiators > Page 7354 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement Heater Core: Service and Repair Heater Case/Cover Replacement HEATER CORE COVER REPLACEMENT REMOVAL PROCEDURE 1. Remove the RH Instrument Panel Closeout/Insulator panel. 2. Remove the LH Instrument Panel Closeout/Insulator panel. 3. Remove the floor carpet. 4. Remove the rear floor air outlet duct from the holes in the floor reinforcement. 5. Disconnect the rear floor air outlet duct from the heater air outlet cover. 6. Remove the rear floor air outlet duct. 7. Remove the heater air outlet cover screws (2). 8. Remove the heater air outlet cover heat stakes (1) with a small chisel. 9. Remove the heater air outlet cover from the HVAC module assembly. 10. Remove the heater core cover screws (2). 11. Remove the heater core cover heat stakes (1) with a small chisel. 12. Remove the heater core cover from the HVAC module assembly. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 7357 1. From the inside of the heater core cover, drill the dimples adjacent to the heat stakes using a 5.5 mm (7/32 in) drill bit. 2. Install the heater core cover to the HVAC module assembly. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the heater core cover screws (2). Tighten Tighten all screws to 1.5 N.m (13 lb in). 4. From the inside of the heater air outlet cover, drill the dimples adjacent to the heat stakes using a 5.5 mm (7/32 in) drill bit. 5. Install the heater air outlet cover. 6. Install the heater air outlet cover screws (2). Tighten Tighten the screws to 1.5 N.m (13 lb in). 7. Connect the rear floor air outlet duct to the heater air outlet cover. 8. Install the rear floor air outlet duct to the holes in the floor reinforcement. 9. Install the floor carpet. 10. Install the RH Instrument Panel Closeout/Insulator panel. 11. Install the LH Instrument Panel Closeout/Insulator panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 7358 Heater Core: Service and Repair Heater Core Replacement HEATER CORE REPLACEMENT TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Remove the fuel injector sight shield. 2. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 3. Use J 38185 in order to position aside the heater hose inlet and outlet clamps at the heater core. 4. Disconnect the inlet and outlet heater hose from the heater core. 5. Remove the RH Instrument Panel Closeout/Insulator panel. 6. Remove the LH Instrument Panel Closeout/Insulator panel 7. Remove the floor carpet. 8. Remove the rear floor air outlet duct from the holes in the floor reinforcement. 9. Disconnect the rear floor air outlet duct from the heater air outlet cover. 10. Remove the rear floor air outlet duct. 11. Remove the heater air outlet cover screws (2). 12. Remove the heater air outlet cover heat stakes (1) with a small chisel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 7359 13. Remove the heater air outlet cover from the HVAC module assembly. 14. Remove the heater core cover screws (2). 15. Remove the heater core cover heat stakes (1) with a small chisel. 16. Remove the heater core cover from the HVAC module assembly. 17. Remove the heater core from the HVAC module assembly. 18. Remove the heater core foam seal (1) from the HVAC module assembly. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 7360 1. Install a new heater core foam seal (1) to the HVAC module assembly. 2. Install the heater core to the HVAC module assembly. 3. From the inside of the heater core cover, drill the dimples adjacent to the heat stakes using a 5.5 mm (7/32 in) drill bit. 4. Install the heater core cover to the HVAC module assembly. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the heater core cover screws (2). Tighten Tighten all screws to 1.5 N.m (13 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair > Heater Case/Cover Replacement > Page 7361 6. From the inside of the heater air outlet cover, drill the dimples adjacent to the heat stakes using a 5.5 mm (7/32 in) drill bit. 7. Install the heater air outlet cover. 8. Install the heater air outlet cover screws (2). Tighten Tighten the screws to 1.5 N.m (13 lb in). 9. Connect the rear floor air outlet duct to the heater air outlet cover. 10. Install the rear floor air outlet duct to the holes in the floor reinforcement. 11. Install the floor carpet. 12. Install the RH Instrument Panel Closeout/Insulator panel. 13. Install the LH Instrument Panel Closeout/Insulator panel. 14. Connect the inlet and outlet heater hose to the heater core. 15. Use J 38185 in order to reposition the heater hose inlet and outlet clamps to the heater core. 16. Install the fuel injector sight shield. 17. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet Heater Hose: Service and Repair Heater Hose Replacement - Inlet HEATER HOSE REPLACEMENT - INLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the fuel injector sight shield. 3. Use J 38185 in order to position aside the heater hose inlet clamp at the pipe adapter. 4. Disconnect the heater inlet hose from the pipe adapter. 5. Use J 38185 in order to position aside the heater core inlet hose clamp. 6. Disconnect the heater inlet hose from the heater core. 7. Remove the heater inlet hose from the support bracket. INSTALLATION PROCEDURE 1. Install the heater inlet hose to the support bracket. 2. Connect the heater inlet hose to the heater core. 3. Use J 38185 in order to secure the heater core hose inlet clamp. 4. Connect the heater inlet hose to the pipe adapter. 5. Use J 38185 in order to secure the heater hose inlet clamp. 6. Install the fuel injector sight shield. 7. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 7366 Heater Hose: Service and Repair Heater Hose Replacement - Outlet HEATER HOSE REPLACEMENT - OUTLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the fuel injector sight shield. 3. Use J 38185 in order to position aside the heater hose outlet clamp at the pipe adapter. 4. Disconnect the heater outlet hose from the pipe adapter. 5. Use J 38185 in order to position aside the heater core outlet hose clamp. 6. Disconnect the heater outlet hose from the heater core. 7. Remove the heater outlet hose from the support bracket. INSTALLATION PROCEDURE 1. Install the heater outlet hose to the support bracket. 2. Connect the heater outlet hose to the heater core. 3. Use J 38185 in order to secure the heater core hose outlet clamp. 4. Connect the heater outlet hose to the pipe adapter. 5. Use J 38185 in order to secure the heater hose outlet clamp. 6. Install the fuel injector sight shield. 7. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 7367 Heater Hose: Service and Repair Heater Pipe Replacement - Inlet HEATER PIPE ADAPTER REPLACEMENT - INLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the fuel injector sight shield. 3. Use J 38185 in order to position aside the heater hose clamp. 4. Disconnect the heater inlet hose from the heater pipe adapter. 5. Remove the heater pipe adapter mounting bolt. 6. Remove the heater pipe adapter. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 7368 1. Lubricate the O-ring seal with Dex-Cool antifreeze. 2. Install the heater pipe adapter. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the heater inlet pipe adapter mounting bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Connect the inlet hose to the heater pipe adapter. 5. Use J 38185 in order to secure the heater core hose clamp. 6. Install the fuel injector sight shield. 7. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 7369 Heater Hose: Service and Repair Heater Pipe Adapter Replacement - Outlet HEATER PIPE ADAPTER REPLACEMENT - OUTLET TOOLS REQUIRED J 38185 Hose Clamp Pliers REMOVAL PROCEDURE 1. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 2. Remove the fuel injector sight shield. 3. Use J 38185 in order to position aside the heater hose clamp. 4. Remove the heater outlet hose from the heater pipe adapter. 5. Remove the heater pipe adapter mounting bolt. 6. Remove the heater pipe adapter. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair > Heater Hose Replacement - Inlet > Page 7370 1. Lubricate the O-ring seal with Dex-Cool antifreeze. 2. Install the heater pipe adapter. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the heater outlet pipe adapter mounting bolt. Tighten Tighten the bolt to 6 N.m (53 lb in). 4. Install the heater outlet hose to the pipe adapter. 5. Use J 38185 in order to secure the heater core hose clamp. 6. Install the fuel injector sight shield. 7. Refill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair High Pressure Safety Valve HVAC: Service and Repair COMPRESSOR PRESSURE RELIEF VALVE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Raise and support the vehicle. Refer to Vehicle Lifting. IMPORTANT: Cap or tape the open A/C components immediately to prevent system contamination. 3. Remove the high pressure relief valve. 4. Cap or tape the A/C compressor. INSTALLATION PROCEDURE 1. Remove the cap or tape from the A/C compressor. 2. Lubricate the O-ring on the high pressure relief valve. Refer to O-Ring Replacement. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the high pressure relief valve. Tighten Tighten the valve to 8 N.m (70 lb in). 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information > Service and Repair > Page 7374 5. Evacuate and recharge the refrigerant system. Refer to Refrigerant Recovery and Recharging. 6. Leak test the fittings of the component using J 39400-A. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector Hose/Line HVAC: Service and Repair A/C Line/Tube Connector A/C LINE/TUBE CONNECTOR REMOVAL/REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. 2. Locate the A/C coupling assembly's locking tab access slots (1). IMPORTANT: When separating the A/C coupling assembly, apply light pressure between the two halves of the coupling to prevent the locking tabs from reengaging. 3. Carefully insert a small flat bladed screwdriver into the first locking tab access slot and gently lift the locking tab to release the lock. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector > Page 7379 4. Carefully insert a small flat bladed screwdriver into the second locking tab access slot and gently lift the locking tab to release the lock. 5. Open and remove the A/C coupling assembly from the A/C refrigerant component. INSTALLATION PROCEDURE IMPORTANT: Inspect the A/C coupling assembly locking tabs for damage or wear. Replace the A/C coupler assembly if any conditions exist. 1. Install the A/C coupling assembly to the A/C refrigerant component. IMPORTANT: Ensure that the A/C coupling assembly is latched securely to the A/C refrigerant component. 2. Close the A/C coupling assembly. 3. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 4. Leak test the fittings of the component using J 39400-A. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector > Page 7380 Hose/Line HVAC: Service and Repair Compressor Hose Assembly Replacement COMPRESSOR HOSE ASSEMBLY REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner assembly. 3. Remove the A/C compressor hose nut from the condenser. 4. Disconnect the A/C compressor hose from the condenser. 5. Remove the A/C compressor hose nut from the compressor hose block to evaporator tube. 6. Remove the A/C compressor hose from the evaporator tube. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector > Page 7381 7. Remove the lower air deflector. 8. Remove the A/C compressor hose nut from the A/C compressor. 9. Remove the A/C compressor hose from the A/C compressor. 10. Remove and discard all sealing washers. INSTALLATION PROCEDURE 1. Install new sealing washers onto the A/C compressor hose assembly. 2. Install the A/C compressor hose to the A/C compressor. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the A/C compressor hose nut to the A/C compressor. Tighten Tighten the nut to 27 N.m (20 lb ft). 4. Install the lower air deflector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector > Page 7382 5. Install new seals washers to the A/C compressor hose assembly and evaporator tube. 6. Install the A/C compressor hose to the evaporator tube. 7. Install the A/C compressor hose to evaporator tube nut. Tighten Tighten the nut to 16 N.m (12 lb ft). 8. Install the A/C compressor hose to the condenser. 9. Install the A/C compressor hose nut to the condenser. Tighten Tighten the nut to 16 N.m (12 lb ft). 10. Install the air cleaner assembly. 11. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 12. Leak test the fittings of the component using J 39400-A. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector > Page 7383 Hose/Line HVAC: Service and Repair Evaporator Tube Replacement EVAPORATOR TUBE REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner assembly. 3. Remove the bolt from the ground wire below the air cleaner assembly. 4. Remove the brake pressure modulator valve bracket. 5. Disconnect the electrical connector from the brake fluid level sensor. 6. Remove the oxygen sensor connector from the fuel injector sight shield rear bracket. 7. Remove the master cylinder mounting nuts. 8. Remove the master cylinder from the brake booster and position aside. 9. Remove the engine vacuum line from the brake booster. 10. Remove the A/C line coupling from the evaporator tube to receiver dehydrator tube (1). 11. Remove the receiver dehydrator mounting bolt (2). 12. Disconnect the receiver dehydrator from the evaporator tube. 13. Remove the block fitting nut that secures the evaporator tube to the A/C compressor hose assembly. 14. Disconnect the evaporator tube from the A/C compressor hose assembly. 15. Remove the block fitting nut (1) that secures the evaporator tube to the TXV. 16. Remove the heater hoses from the support bracket and position aside. 17. Remove the transmission shift cable from the retainer above the heater hoses and position the cable aside. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector > Page 7384 18. Disconnect the evaporator tube from the TXV. 19. Remove the evaporator tube from the support clip (1) on the left fender rail. 20. Remove the transaxle fluid filler tube. 21. Disconnect the wire harness electrical connector from the A/C pressure sensor. 22. Disconnect the wire harness electrical connector C101 near the top of the left shock tower. 23. Remove the evaporator tube from the vehicle. 24. Remove the A/C pressure sensor. 25. Remove and discard the O-ring seals and seal washers. INSTALLATION PROCEDURE 1. Replace the O-ring seal on the receiver dehydrator and A/C pressure sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the A/C pressure sensor to the evaporator line. Tighten Tighten the sensor to 4.7 N.m (41 lb in). 3. Replace the seal washers on the evaporator tube. 4. Install the evaporator tube to the vehicle. 5. Install the transaxle fluid filler tube. 6. Connect the evaporator tube to the support clip (1) on the left fender rail. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector > Page 7385 7. Connect the evaporator tube to the TXV. 8. Install the evaporator tube to TXV nut (1). Tighten Tighten the nut to 27 N.m (20 lb ft). 9. Install the oxygen sensor connector to the fuel injector sight shield rear bracket. 10. Install the heater hoses to the support bracket. 11. Install the transmission shift cable to the retainer above the heater hoses. 12. Connect the receiver dehydrator to the evaporator tube. 13. Install the A/C line coupling to the evaporator tube and receiver dehydrator tube (1). 14. Install the receiver dehydrator mounting bolt (2). Tighten Tighten the bolt to 4 N.m (36 lb in). 15. Connect the A/C compressor hose assembly to the evaporator tube. 16. Install the A/C compressor hose assembly to evaporator tube block fitting nut. Tighten Tighten the nut to 16 N.m (12 lb ft). 17. Install the brake pressure modulator valve bracket. 18. Install the master cylinder to the brake booster. 19. Install the nuts to the master cylinder. Tighten Tighten the nuts to 25 N.m (18 lb ft). 20. Connect the electrical connector to the brake fluid level sensor. 21. Install the engine vacuum line to the brake booster. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and Repair > A/C Line/Tube Connector > Page 7386 22. Connect the wire harness electrical connector C101 near the top of the left shock tower. 23. Install the bolt to the ground wire below the air cleaner assembly. Tighten Tighten the bolt to 10 N.m (89 in lb). 24. Install the air cleaner assembly. 25. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 26. Leak test the fittings of the component using J 39400-A. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair Housing Assembly HVAC: Service and Repair HVAC MODULE ASSEMBLY REPLACEMENT TOOLS REQUIRED - J 39400-A Halogen Leak Detector - J 38185 Hose Clamp Pliers REMOVAL PROCEDURE CAUTION: Refer to Battery Disconnect Caution in Service Precautions. 1. Disconnect the battery negative cable. 2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 3. Drain the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 4. Use J 38185 in order to position aside the heater hose inlet and outlet clamp at the heater core. 5. Disconnect the inlet and outlet heater hose from the heater core. 6. Remove the evaporator tube to TXV block fitting nut (1). 7. Disconnect the evaporator tube from the TXV. 8. Remove and discard the seal washers. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 7390 9. Remove the I/P lower trim panel. 10. Remove the retaining screw (1) from the panel air duct. 11. Remove the retaining bolts from the panel air duct. 12. Remove the panel air duct from the cross vehicle beam. 13. Remove the retaining bolts from the right air duct. 14. Remove the right air duct from the cross vehicle beam. 15. Remove the bolts from the left side fuse block to cross vehicle beam. 16. Remove the left side fuse block wire harness from the cross vehicle beam. 17. Position the left side fuse block aside. 18. Disconnect the wire harness connectors from the body control module. 19. Disconnect the body control module from the cross vehicle beam. 20. Remove the body control module from the vehicle. 21. Disconnect any ground wires, as necessary. 22. Remove the bolt from the right side fuse block to cross vehicle beam. 23. Remove the right side fuse block wire harness from the cross vehicle beam. 24. Position the right side fuse block aside. 25. Remove the brake pedal. 26. Remove the 3 bolts from the brake pedal bracket to cross vehicle beam. 27. Disconnect the electrical connector from the HVAC module assembly to main wire harness connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 7391 28. Release the wiring harness retaining clips from the cross vehicle beam and position the wiring harness aside. 29. Remove the bolts from the HVAC module assembly upper support. 30. Remove the bolt (1) from the HVAC module assembly lower support. 31. Remove the bolt (2) from the the HVAC module assembly lower support. 32. Remove the bolts from the right and left side of the cross vehicle beam. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 7392 33. Remove the cross vehicle beam. 34. Remove the evaporator drain elbow. 35. Remove the nuts which secure the HVAC module assembly to the dash. 36. Remove the HVAC module assembly: 36.1. Pull the HVAC module assembly rearward to disengage the mounting studs from the dash panel. 36.2. Position aside the dash insulator pad from the recirculation opening of the HVAC module assembly. 36.3. Roll the HVAC module assembly downward and rearward to disconnect the heater core outlet cover from the rear floor air outlet duct. 36.4. Remove the HVAC module assembly. 37. Remove and discard all of the seals (1,2,3) from the outer HVAC module assembly. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 7393 1. Install new seals (1,2,3) to the outer HVAC module assembly. IMPORTANT: When installing the HVAC control module, ensure that the dash insulator pad cut-outs and the HVAC seals, studs, and drain align and seal properly to the dash panel. 2. Install the HVAC module assembly into the vehicle: 2.1. Align the heater core outlet cover to the rear floor air outlet duct. 2.2. Roll the HVAC module assembly forward and upward and align the dash insulator pad to the recirculation opening of the HVAC module assembly. 2.3. Align the mounting studs and the drain on the HVAC module assembly to seat against the dash panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts which secure the HVAC module assembly to the dash. Tighten Tighten the nuts to 10 N.m (89 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 7394 4. Install the evaporator drain elbow. 5. Install the cross vehicle beam to the vehicle. 6. Install the bolts to the right and left side of the cross vehicle beam. 7. Tighten the bolts to the right and left side of the cross vehicle beam in sequence. Tighten Tighten the bolts to 25 N.m (18 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 7395 8. Install the bolts to the HVAC module assembly upper support. Tighten Tighten the bolts to 4 N.m (35 lb in). 9. Install the bolt to the HVAC module assembly lower support (1). Tighten Tighten the bolt to 4 N.m (35 lb in). 10. Install the bolt to the HVAC module assembly lower support (2). Tighten Tighten the bolt to 4 N.m (35 lb in). 11. Reposition the I/P wiring harness on to the cross vehicle beam and secure the retaining clips. 12. Connect the electrical connector from the HVAC module assembly to main wire harness connector. 13. Install the 3 bolts through the brake pedal bracket to the cross vehicle beam. Tighten Tighten the bolts to 50 N.m (37 lb ft). 14. Install the brake pedal. 15. Connect all disconnected ground wires. 16. Install the body control module to the cross vehicle beam. 17. Connect the wire harness connectors to the body control module. 18. Install the left side fuse block to the cross vehicle beam. 19. Install the bolts to the left side fuse block. Tighten Tighten the bolts to 10 N.m (89 in lb). 20. Install the right side fuse block to the cross vehicle beam. 21. Install the bolt to the right side fuse block. Tighten Tighten the bolt to 10 N.m (89 in lb). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 7396 22. Install the right air duct to the cross vehicle beam. 23. Install the right air duct bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 24. Install the panel air duct to the cross vehicle beam. 25. Install the panel air duct screw (1). Tighten Tighten the screw to 1.8 N.m (16 lb in). 26. Install the panel air duct bolts. Tighten Tighten the bolts to 10 N.m (89 lb in). 27. Install the I/P lower trim panel. 28. Install new seal washers on the evaporator tube. 29. Connect the evaporator tube to the TXV. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service and Repair > Page 7397 30. Install the evaporator tube to TXV block fitting nut (1). Tighten Tighten the nut to 27 N.m (20 lb ft). 31. Connect the inlet and outlet heater hose to the heater core. IMPORTANT: Reposition the heater core hose clamps in the indicated location. 32. Use J 38185 in order to reposition the heater hose inlet and outlet clamp to the heater core. 33. Fill the cooling system. Refer to Draining and Filling Cooling System in Cooling System. 34. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 35. Connect the battery negative cable. 36. Leak test the fittings of the component using J 39400-A. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair Receiver Dryer: Service and Repair RECEIVER DEHYDRATOR REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 2. Remove the air cleaner assembly. 3. Remove the A/C tube coupling from the receiver dehydrator tube to evaporator tube.See: Hose/Line HVAC/Service and Repair/A/C Line/Tube Connector 4. Remove the A/C tube coupling from the receiver dehydrator tube to condenser tube. 5. Disconnect the receiver dehydrator tube from the condenser. 6. Remove the receiver dehydrator mounting bolt (2). 7. Disconnect the receiver dehydrator from the evaporator tube. 8. Remove the receiver dehydrator. 9. Remove and discard the O-ring seals. INSTALLATION PROCEDURE 1. If replacing the receiver dehydrator, add refrigerant oil to the receiver dehydrator. Refer to Refrigerant System Capacities for system capacity information. 2. Install the new O-ring seals onto the receiver dehydrator tubes. 3. Connect the receiver dehydrator tube to the evaporator tube. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Service and Repair > Page 7401 4. Install the A/C tube coupling over the connection between the evaporator tube and the receiver dehydrator tube. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the receiver dehydrator mounting bolt (2). Tighten Tighten the bolt to 4 N.m (36 lb in). 6. Connect the receiver dehydrator tube to the condenser. 7. Install the A/C tube coupling over the connection between the condenser tube and the receiver dehydrator tube. 8. Install the air cleaner assembly. 9. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging. 10. Leak test the fittings of the component using J 39400-A. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment Refrigerant: Technical Service Bulletins A/C - Refrigerant Recovery/Recycling/Equipment Bulletin No.: 08-01-38-001 Date: January 25, 2008 INFORMATION Subject: Information On New GE-48800 CoolTech Refrigerant Recovery/Recharge Equipment Models: 2008 and Prior GM Passenger Cars and Light Duty Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2005-2008 Saab 9-7X Attention: This bulletin is being issued to announce the release of GM approved Air Conditioning (A/C) Refrigerant Recovery and Recharging Equipment that meets the new Society of Automotive Engineers (SAE) J2788 Refrigerant Recovery Standards. The ACR2000 (J-43600) cannot be manufactured in its current state after December 2007 and will be superseded by GE-48800. The new J2788 standard does not require that GM Dealers replace their ACR2000 units. ACR2000's currently in use are very capable of servicing today's refrigerant systems when used correctly and can continue to be used. Details regarding the new SAE J2788 standard are outlined in GM Bulletin 07-01-38-004. Effective February 1 2008, new A/C Refrigerant Recovery/Recharging equipment (P/N GE-48800) will be released as a required replacement for the previously essential ACR2000 (J-43600). This equipment is SAE J2788 compliant and meets GM requirements for A/C Refrigerant System Repairs on all General Motors vehicles, including Hybrid systems with Polyolester (POE) refrigerant oil. This equipment will not be shipped as an essential tool to GM Dealerships. In addition, this equipment is Hybrid compliant and designed to prevent oil cross contamination when servicing Hybrid vehicles with Electric A/C Compressors that use POE refrigerant oil. The ACR2000 (J-43600) will need to be retrofitted with a J-43600-50 (Hose - ACR2000 Oil Flush Loop) to be able to perform Hybrid A/C service work. All Hybrid dealers will receive the J-43600-50, with installation instructions, as a component of the Hybrid essential tool package. Dealerships that do not sell Hybrids, but may need to service Hybrids, can obtain J-43600-50 from SPX Kent Moore. Refer to GM Bulletin 08-01-39-001 for the ACR2000 Hose Flush procedure. The High Voltage (HV) electric A/C compressor used on Two Mode Hybrid vehicles uses a Polyolester (POE) refrigerant oil instead of a Polyalkylene Glycol (PAG) synthetic refrigerant oil. This is due to the better electrical resistance of the POE oil and its ability to provide HV isolation. Failure to flush the hoses before adding refrigerant to a Hybrid vehicle with an electric A/C compressor may result in an unacceptable amount of PAG oil entering the refrigerant system. It may cause a Battery Energy Control Module Hybrid Battery Voltage System Isolation Lost Diagnostic Trouble Code (DTC P1AE7) to be set. Additionally, the A/C system warranty will be voided. Warranty Submission Requirements The Electronically Generated Repair Data (snapshot summary) and printer functions have been eliminated from the GE-48800. The VGA display and temperature probes were eliminated to reduce equipment costs. As a result, effective immediately the 18 digit "Snapshot/Charge Summary" code is no longer required for Air Conditioning (A/C) refrigerant system repairs that are submitted for warranty reimbursement. The charge summary data from before and after system repairs will continue to required, but documented on the repair order only. Both high and low pressures and the recovery and charge amounts should be noted during the repair and entered on the repair order. If using ACR2000 (J-43600), the "Snapshot/Charge Summary" printouts should continue to be attached to the shops copy of the repair order. The labor codes that are affected by this requirement are D3000 through D4500. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 7406 Refrigerant: Technical Service Bulletins A/C - Contaminated R134A Refrigerant Bulletin No.: 06-01-39-007 Date: July 25, 2006 INFORMATION Subject: Contaminated R134a Refrigerant Found on Market for Automotive Air-Conditioning Systems Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X Attention: This bulletin should be directed to the Service Manager as well as the Parts Manager. Commercially Available Contaminated R134a Refrigerant Impurities have been found in new commercially available containers of R134a. High levels of contaminates may cause decreased performance, and be detrimental to some air-conditioning components. Accompanying these contaminates has been high levels of moisture. Tip: Excessive moisture may cause system concerns such as orifice tube freeze-up and reduced performance. Industry Reaction: New Industry Purity Standards Due to the potential availability of these lower quality refrigerants, the Society of Automotive Engineers (SAE), and the Air Conditioning and Refrigeration Industry (ARI) are in the process of instituting reliable standards that will be carried on the labels of future R134a refrigerant containers. This identifying symbol will be your assurance of a product that conforms to the minimum standard for OEM Automotive Air-Conditioning use. How Can You Protect Yourself Today? It is recommended to use GM or ACDelco(R) sourced refrigerants for all A/C repair work. These refrigerants meet General Motors own internal standards for quality and purity, insuring that your completed repairs are as good as the way it left the factory. Parts Information The part numbers shown are available through GMSPO or ACDelco(R). The nearest ACDelco(R) distributor in your area can be found by calling 1-800-223-3526 (U.S. Only). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Refrigerant Recovery/Recycling/Equipment > Page 7407 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Air Conditioning Refrigerant ................................................................................................................ ......................................................... 2.4 lb. (1.1 kg.) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 7410 Refrigerant: Fluid Type Specifications Air Conditioning Refrigerant ....................................................................................................................... R134a P/N 12356150 U.S. (10953485 Canada) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page 7411 Refrigerant: Service and Repair REFRIGERANT RECOVERY AND RECHARGING TOOLS REQUIRED - J 43600 ACR 2000 Air Conditioning Service Center - J 45037 A/C Oil Injector CAUTION: - Avoid breathing the A/C Refrigerant 134a (R-134a) and the lubricant vapor or the mist. Exposure may irritate the eyes, nose, and throat. Work in a well ventilated area. In order to remove R-134a from the A/C system, use service equipment that is certified to meet the requirements of SAE J 2210 (R-134a recycling equipment). If an accidental system discharge occurs, ventilate the work area before continuing service. Additional health and safety information may be obtained from the refrigerant and lubricant manufacturers. - For personal protection, goggles and gloves should be worn and a clean cloth wrapped around fittings, valves, and connections when doing work that includes opening the refrigerant system. If R-134a comes in contact with any part of the body severe frostbite and personal injury can result. The exposed area should be flushed immediately with cold water and prompt medical help should be obtained. NOTE: - R-134a is the only approved refrigerant for use in this vehicle. The use of any other refrigerant may result in poor system performance or component failure. - To avoid system damage use only R-134a dedicated tools when servicing the A/C system. - Use only Polyalkylene Glycol Synthetic Refrigerant Oil (PAG) for internal circulation through the R-134a A/C system and only 525 viscosity mineral oil on fitting threads and O-rings. If lubricants other than those specified are used, compressor failure and/or fitting seizure may result. - R-12 refrigerant and R-134a refrigerant must never be mixed, even in the smallest of amounts, as they are incompatible with each other. If the refrigerants are mixed, compressor failure is likely to occur. Refer to the manufacturer instructions included with the service equipment before servicing. The J 43600 is a complete air conditioning service center for R-134a. The ACR 2000 recovers, recycles, evacuates and recharges A/C refrigerant quickly, accurately and automatically. The unit has a display screen that contains the function controls and displays prompts that will lead the technician through the recover, recycle, evacuate and recharge operations. R-134a is recovered into and charged out of an internal storage vessel. The ACR 2000 automatically replenishes this vessel from an external source tank in order to maintain a constant 5.45-6.82 kg (12-15 lbs) of A/C refrigerant. The ACR 2000 has a built in A/C refrigerant identifier that will test for contamination, prior to recovery and will notify the technician if there are foreign gases present in the A/C system. If foreign gases are present, the ACR 2000 will not recover the refrigerant from the A/C system. The ACR 2000 also features automatic air purge, single pass recycling and an automatic oil drain. Refer to the J 43600 ACR 2000 manual for operation and setup instruction. Always recharge the A/C System with the proper amount of R-134a. Refer to Refrigerant System Capacities for the correct amount. A/C Refrigerant System Oil Charge Replenishing If oil was removed from the A/C system during the recovery process or due to component replacement, the oil must be replenished. Oil can be injected into a charged system using J 45037. For the proper quantities of oil to add to the A/C refrigerant system, refer to Refrigerant System Capacities. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C - New PAG Oil Refrigerant Oil: Technical Service Bulletins A/C - New PAG Oil Bulletin No.: 02-01-39-004B Date: November 16, 2005 INFORMATION Subject: New PAG Oil Released Models: 2006 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 2005-2006 Saab 9-7X Built With R-134a Refrigeration System All Air Conditioning Compressor Types (Excluding R4 and A6 Type Compressors) Supercede: This bulletin is being revised to change the PAG oil part number used for R4 and A6 compressors with R-134a refrigerant systems. Please discard Corporate Bulletin Number 02-01-39-004A (Section 01 - HVAC). All General Motors vehicles built with R-134a refrigerant systems shall now be serviced with GM Universal PAG Oil (excluding vehicles equipped with an R4 or A6 compressor). R4 and A6 compressors with R-134a refrigerant systems shall use PAG OIL, GM P/N 12356151 (A/C Delco part number 15-118) (in Canada, use P/N 10953486). Important: The PAG oil referenced in this bulletin is formulated with specific additive packages that meet General Motors specifications and use of another oil may void the A/C systems warranty. Use this new PAG oil when servicing the A/C system on the vehicles listed above. Oil packaged in an 8 oz tube should be installed using A/C Oil Injector, J 45037. Refer to the HVAC Section of Service Information for detailed information on Oil Balancing and Capacities. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications REFRIGERANT OIL CAPACITIES A/C COMPRESSOR REPLACEMENT ................................................................................................................................................. 75 ml (2.5 oz) NOTE: The 7CVC service compressor is shipped with 5.0 oz of PAG oil. If more than the specified amount of PAG oil was drained from a component, add the amount drained. IMPORTANT: Compressor failure can occur if the oil removed during refrigerant recovery is not replaced. CONDENSER REPLACEMENT ............................................................................................................................................................ 60 ml (2.0 oz) EVAPORATOR REPLACEMENT ......................................................................................................................................................... 90 ml (3.0 oz) RECEIVER DEHYDRATOR REPLACEMENT ................................................................................................................................... 30 ml (1.0 oz) NOTE: Add PAG oil equal to the amount of oil drained from the old receiver dehydrator, plus the specified amount. ANY LINE SET (HOSE/TUBE OR TUBE ASSEMBLY)....................................................................................................................... 30 ml (1.0 oz) TOTAL SYSTEM PAG OIL CAPACITY ......................................................................................................................................... 240.0 ml (8.0 oz) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 7418 Refrigerant Oil: Fluid Type Specifications REFRIGERANT OIL PAG Oil GM P/N 12378526 (Canadian P/N 88900060) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7422 Left Front Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7423 Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7424 A/C Refrigerant Pressure Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7425 Refrigerant Pressure Sensor / Switch: Description and Operation A/C REFRIGERANT PRESSURE SENSOR The A/C refrigerant pressure sensor is a 3-wire piezoelectric pressure transducer. A 5-volt reference, low reference, and signal circuits enable the sensor to operate. The A/C pressure signal can be between 0-5 volts. When the A/C refrigerant pressure is low, the signal value is near 0 volts. When the A/C refrigerant pressure is high, the signal value is near 5 volts. The A/C refrigerant pressure sensor protects the A/C system from operating when an excessively high or low pressure condition exists. The PCM disables the compressor clutch under the following conditions: - A/C pressure is more than 3034 kPa (440 psi). The clutch will be enabled after the pressure decreases to less than 2068 kPa (300 psi). - A/C pressure is less than 241 kPa (35 psi). The clutch will be enabled after the pressure increases to more than 248 kPa (36 psi). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7426 Refrigerant Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) REFRIGERANT PRESSURE SENSOR REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner assembly. 2. Disconnect the electrical connector from the A/C refrigerant pressure sensor. 3. Remove the A/C refrigerant pressure sensor from the evaporator tube. INSTALLATION PROCEDURE 1. Replace the O-ring seal for the A/C refrigerant pressure sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the A/C refrigerant pressure sensor to the evaporator tube. Tighten Tighten the sensor to 4.7 N.m (41 lb in). 3. Connect the electrical connector to the A/C refrigerant pressure sensor. 4. Install the air cleaner assembly. 5. Leak test the fittings of the component using J 39400-A. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Service and Repair Compressor Clutch Relay: Service and Repair COMPRESSOR RELAY REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Remove the underhood lower relay cover. 3. Remove the A/C compressor control relay from the electrical center. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Service and Repair > Page 7431 1. Install the A/C compressor control relay into the electrical center. 2. Install the underhood lower relay cover. 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations Middle Center Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 7435 Control Module HVAC: Diagrams HVAC Control Module Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 7436 HVAC Control Module Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 7437 HVAC Control Module Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 7438 Control Module HVAC: Description and Operation HVAC CONTROL MODULE The HVAC control module is a Class 2 device that interfaces between the operator and the HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all HVAC DTCs and settings will be erased from KAM. The control module supports the following features: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Locations > Page 7439 Control Module HVAC: Service and Repair BLOWER CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the right side instrument panel insulator. 2. Disconnect the electrical connector from the blower control module. 3. Remove the two heat stakes from the blower control module using a small chisel. 4. Remove the blower control module. INSTALLATION PROCEDURE 1. Install the blower control module. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the two new screws in the pre drilled holes to the side of the heat stakes in the blower control module and HVAC module assembly. Tighten Tighten the screws to 1.5 N.m (13 lb in). 3. Connect the electrical connector to the blower control module. 4. Install the right side instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations Front Of Vehicle Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7444 Ambient Air Temperature Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor / Switch HVAC > Component Information > Locations > Page 7445 Ambient Temperature Sensor / Switch HVAC: Service and Repair AMBIENT AIR TEMPERATURE GAGE SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the electrical connector from the ambient temperature sensor that is located on the front radiator air baffle. 3. Remove the ambient temperature sensor from the radiator air baffle. INSTALLATION PROCEDURE 1. Install the ambient temperature sensor to the radiator air baffle. 2. Connect the electrical connector to the ambient temperature sensor. 3. Lower the vehicle. 4. Drive the vehicle at a speed of 32 km/h (20 mph) for approximately 1 1/2 minutes or at a speed of 72 km/h (45 mph) for approximately 1 minute in order to obtain the ambient update. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations Refrigerant Pressure Sensor / Switch: Locations Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7449 Left Front Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7450 Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7451 A/C Refrigerant Pressure Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7452 Refrigerant Pressure Sensor / Switch: Description and Operation A/C REFRIGERANT PRESSURE SENSOR The A/C refrigerant pressure sensor is a 3-wire piezoelectric pressure transducer. A 5-volt reference, low reference, and signal circuits enable the sensor to operate. The A/C pressure signal can be between 0-5 volts. When the A/C refrigerant pressure is low, the signal value is near 0 volts. When the A/C refrigerant pressure is high, the signal value is near 5 volts. The A/C refrigerant pressure sensor protects the A/C system from operating when an excessively high or low pressure condition exists. The PCM disables the compressor clutch under the following conditions: - A/C pressure is more than 3034 kPa (440 psi). The clutch will be enabled after the pressure decreases to less than 2068 kPa (300 psi). - A/C pressure is less than 241 kPa (35 psi). The clutch will be enabled after the pressure increases to more than 248 kPa (36 psi). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Locations > Page 7453 Refrigerant Pressure Sensor / Switch: Service and Repair AIR CONDITIONING (A/C) REFRIGERANT PRESSURE SENSOR REPLACEMENT TOOLS REQUIRED J 39400-A Halogen Leak Detector REMOVAL PROCEDURE 1. Remove the air cleaner assembly. 2. Disconnect the electrical connector from the A/C refrigerant pressure sensor. 3. Remove the A/C refrigerant pressure sensor from the evaporator tube. INSTALLATION PROCEDURE 1. Replace the O-ring seal for the A/C refrigerant pressure sensor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the A/C refrigerant pressure sensor to the evaporator tube. Tighten Tighten the sensor to 4.7 N.m (41 lb in). 3. Connect the electrical connector to the A/C refrigerant pressure sensor. 4. Install the air cleaner assembly. 5. Leak test the fittings of the component using J 39400-A. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Service and Repair Service Port HVAC: Service and Repair SERVICE PORTS REPLACEMENT TOOLS REQUIRED J 39037Charge Valve Octagon Socket REMOVAL PROCEDURE 1. Remove the service port cap. 2. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging. 3. Use the J 39037 to remove the service port. INSTALLATION PROCEDURE 1. Replace the O-ring. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the service port valve. Tighten Tighten the valve to 11 N.m (98 lb in). 3. Evacuate and charge the system. Refer to Refrigerant Recovery and Recharging. 4. Leak test the A/C service port. Refer to Leak Testing. 5. Install the service port cap. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System Repairs and Inspections Required After a Collision: Service and Repair Air Bag System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION CAUTION: Proper operation of the SIR sensing system requires that any repairs to the vehicle structure return the vehicle structure to the original production configuration. Not properly repairing the vehicle structure could cause non-deployment in a collision or deployment for conditions less severe than intended. After any collision, inspect the following components as indicated. If damage is detected, replace the component. If damage to the mounting points or mounting hardware is detected, repair the component or replace the hardware as needed. - Steering column - Perform the steering column accident damage inspection procedures. Refer to Steering Column Accident Damage Inspection in Steering Wheel and Column. - I/P Knee Bolsters and Mounting Points - Inspect the knee bolsters for bending, twisting, buckling, or any other type of damage. - I/P brackets, braces, etc. - Inspect for bending, twisting, buckling, or any other type of damage. - Seat Belts - Perform the seat belt operational and functional checks. Refer to Operational and Functional Checks in Seat Belts. - I/P Cross Car Beam - Inspect for bending, twisting, buckling, or any other type of damage. - I/P Mounting Points and Brackets - Inspect for bending, twisting, buckling, or any other type of damage. - Seats and Seat Mounting Points - Inspect for bending, twisting, buckling, or any other type of damage. Frontal Inflator Module Deployment - Component Replacement and Inspections After a collision involving inflator module deployment, replace the following components. Inflatable restraint I/P module - Inflatable restraint steering wheel module - Inflatable restraint sensing and diagnostic module (SDM) Perform additional inspections on the following components. Inflatable restraint steering wheel module coil and coil wiring pigtail - Inspect for melting, scorching, or other damage due to excessive heat. - Mounting points and mounting hardware for the inflatable restraint I/P module, steering wheel module, and SDM - Inspect for any damage and repair or replace each component as needed. Side Inflator Module Deployment - Component Replacement and Inspections After a collision involving a side inflator module deployment, replace the following components on the side of the impact. Inflatable restraint side impact sensor (SIS) - Inflatable restraint side impact module - Inflatable restraint sensing and diagnostic module (SDM) Perform additional inspections on the following components. - Mounting points or mounting hardware for the inflatable restraint SIS and side impact module on the side of the impact - Inspect for any damage and repair or replace each component as needed. - Mounting points or mounting hardware for the inflatable restraint SDM - Inspect for any damage and repair or replace each component as needed. Sensor Replacement Guidelines The SIS replacement policy requires replacing sensors in the area of accident damage. The area of accident damage is defined as the portion of the vehicle which is crushed, bent, or damaged due to a collision. Replace the sensor whether or not the air bags have deployed. - Replace the sensor even if it appears to be undamaged. Sensor damage which is not visible, such as a slight bending of the mounting bracket or cuts in the wire insulation, can cause improper operation of the sensor. Do not try to determine whether the sensor is undamaged, replace the sensor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 7462 Repairs and Inspections Required After a Collision: Service and Repair Seat Belt System REPAIRS AND INSPECTIONS REQUIRED AFTER A COLLISION CAUTION: Restraint systems can be damaged in a collision. To help avoid injury and ensure that all parts in need of replacement are replaced: - Replace any seat belt system that was in use during the collision serious enough to deploy any automatic restraint device such as air bags and seat belt pretensioners. This not only includes seat belt systems in use by people of adult size, but seat belt systems used to secure child restraints, infant carriers and booster seats, including LATCH system and top tether anchorages. - Replace any seat belt system that has torn, worn, or damaged components. This not only includes adult seat belt systems, but built-in child restraints and LATCH system components, if any. - Replace any seat belt system if you observe the words "REPLACE" or "CAUTION", or if a yellow tag is visible. Do not replace a seat belt if only the child seat caution label is visible. - Replace any seat belt system if you are doubtful about its condition. This not only includes adult seat belt systems, but built-in child restraints, LATCH system components, and any restraint system used to secure infant carriers, child restraints, and booster seats. Do NOT replace single seat belt system components in vehicles that have been in a collision as described above. Always replace the entire seat belt system with the buckle, guide and retractor assembly, which includes the latch and webbing material. After a minor collision where no automatic restraint device was deployed, seat belt system replacement may not be necessary, unless some of the parts are torn, worn, or damaged. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Repairs and Inspections Required After a Collision > System Information > Service and Repair > Air Bag System > Page 7463 Repairs and Inspections Required After a Collision: Service and Repair Steering Column Steering Column Accident Damage Inspection ^ Vehicles involved in accidents involving the following conditions may also have a damaged or misaligned steering column: ^ Frame damage ^ Major body or sheet metal damage ^ Where the steering column has been impacted ^ Where supplemental inflatable restraint systems deployed ^ Inspect the capsules on the steering column bracket assembly. All capsules must be securely seated in the bracket slots and inspected for any loose conditions when pushed or pulled by hand. ^ Observe how the bracket is attached to the jacket assembly. ^ If the capsules are not securely seated and the bracket is bolted to the jacket assembly, replace only the bracket. ^ If the capsules are not securely seated and the bracket is welded to the jacket assembly, replace only the jacket assembly. ^ Inspect for jacket assembly collapse by measuring the distance from the lower edge of the upper jacket to a defined point on the lower jacket. Replace the jacket assembly if the measured dimensions are not within specifications. ^ Visually inspect the steering shaft for sheared injected plastic (1). If the steering shaft shows sheared plastic (1), replace the steering shaft. ^ Any frame damage that could cause a bent steering shaft must have the steering shaft runout checked. Using a dial indicator at the lower end of the steering shaft, rotate the steering wheel. The runout must not exceed 1.60 mm (0.06 in.). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Disabling And Enabling Zones Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7469 The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7470 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the radiator upper air baffle and deflector. 7. Remove the orange connector position assurance (CPA) (2) from the yellow sensor harness connector (3). 8. Disconnect the sensor harness connector from the sensor (1). Zone 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7471 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the side impact sensor (SIS)-LF from the center pillar. 7. Remove the connector position assurance (CPA) from the SIS-LF connector (2). 8. Disconnect the SIS-LF connector (2) from the SIS-LF (1). Zone 3 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7472 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the LH insulator panel. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Disconnect the steering wheel module coil connector. Zone 5 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7473 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the RH IP access hole cover. 7. Remove the connector position assurance (CPA) from the inflatable restraint IP module connector located to the right of the steering column. 8. Disconnect the IP module connector. Zone 7 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7474 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the fuse block access cover. 5. Remove the SIR Fuse. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the side impact module - LF connector (1) located under the driver seat. 7. Disconnect the side impact module - LF connector (1). Zone 9 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7475 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the I/P fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the LH insulator panel. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Disconnect the steering wheel module coil connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7476 9. Remove the RH I/P access hole cover. 10. Remove the CPA from the inflatable restraint I/P module connector, located at the RH side of the I/P. 11. Disconnect the I/P module connector. 12. Remove the CPA from the inflatable restraint side impact module - LF connector (1), located under the driver seat. 13. Disconnect the side impact module - LF connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7477 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition. 2. Connect the sensor harness connector (3) to the sensor (1). 3. Install the orange CPA (2) into the yellow sensor harness connector (3). 4. Install the radiator upper air baffle and deflector. 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash seven times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7478 1. Connect the SIS-LF connector (2) to the SIS-LF (1). 2. Install the CPA to the SIS-LF connector(2). 3. Install the side impact sensor (SIS)-LF into the center pillar. 4. Install the SIR Fuse. 5. Install the fuse block access cover. 6. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. 2. Connect the steering wheel module coil connector. 3. Install the CPA from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 4. Install the LH insulator panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7479 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash seven times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the IP module connector. 3. Install the CPA into the IP module connector located to the right of the steering column. 4. Install the LH insulator panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7480 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Connect the inflatable restraint side impact module - LF connector (1) located under the driver seat. 2. Install the CPA to the side impact module - LF connector (1). 3. Remove the SIR Fuse. 4. Install the fuse block access cover. 5. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 5.1. The AIR BAG indicator will flash seven times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7481 1. Remove the key from the ignition. Connect the inflatable restraint side impact module - LF connector (1), located under the driver seat. 2. Install the CPA to the side impact module - LF connector. 3. Connect the inflatable restraint I/P module connector, located at the RH side of the I/P. 4. Install the CPA to the I/P module connector. 5. Install the RH I/P access hole cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7482 6. Connect the steering wheel module coil connector. 7. Install the CPA from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Install the LH insulator panel. 9. Install the SIR Fuse. 10. Install the LH I/P access hole cover. 11. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 11.1. The AIR BAG indicator will flash seven times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Air Bag Harness > Component Information > Description and Operation Air Bag Harness: Description and Operation INFLATABLE RESTRAINT WIRING HARNESS The inflatable restraint wiring harness connects the inflator modules, the SDM, the deployment loops, and the serial data circuit together using weather - packed connectors. SIR system connectors are yellow for easy identification. When repairing SIR wiring harnesses, follow the proper testing and repair procedures. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations SIR Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 7490 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 7491 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 7492 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 7493 Inflatable Restraint Sensing And Diagnostic Module: Service Precautions CAUTION: - Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 7494 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The inflatable restraint sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with external sensors, if equipped, mounted at various locations, depending on vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors, if equipped. The SDM compares the result of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the deployment loops, deploying the inflator modules. The SDM records the SIR system status when a deployment occurs and commands the IPC to turn the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will turn the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 36 volt loop reserve (36 VLR) for deployment of the inflator modules. It is important to note, when disabling the SIR system for service or rescue operations, to allow the 36 VLR to dissipate, which could take up to 1 minute. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) Inflatable Restraint Sensing And Diagnostic Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module (AJ7) REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 9. CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. - Refer to SIR Caution in Service Precautions. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer. Roll back the carpet. 4. Remove the connector position assurance (CPA) from the 8-way wiring harness connector on the sensing and diagnostic module (SDM). 5. Disconnect the 8-way wiring harness connector from the SDM. 6. Remove the CPA from the 18-way wiring harness connector (2). 7. Disconnect the 18-way wiring harness connector from the SDM. 8. Remove the SDM mounting fasteners (3). 9. Remove the SDM (1) from the floor pan (2). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 7497 2. Install the SDM (1) horizontally to the floor pan (2). 3. Point the arrow on the SDM toward the front of the vehicle. 4. Install the SDM mounting fasteners (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fasteners to 10 N.m (89 lb in). 5. Install the 18-way wiring harness connector to the SDM. 6. Install the CPA to the 18-way wiring harness connector. 7. Install the 8-way wiring harness connector to the SDM. 8. Install the CPA to the 8-way wiring harness connector. 9. Install the carpet and the passenger front carpet retainer. 10. Install the passenger front seat. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 9. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 7498 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module (AK5) REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 9. CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. - Refer to SIR Caution in Service Precautions. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer. Roll back the carpet. 4. Remove the connector position assurance (CPA) from the wiring harness connector of the sensing and diagnostic module (SDM). 5. Disconnect the wiring harness connector from the SDM. 6. Remove the SDM mounting fasteners (3). 7. Remove the SDM (1) from the floor pan (2). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 7499 2. Install the SDM (1) horizontally to the floor pan (2). 3. Point the arrow on the SDM toward the front of the vehicle. 4. Install the SDM mounting fasteners (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fasteners to 10 N.m (89 lb in). 5. Install the wiring harness connector to the SDM. 6. Install the CPA to the SDM wiring harness connector. 7. Install the carpet and the passenger front carpet retainer. 8. Install the passenger front seat. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 9. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams Clockspring Assembly / Spiral Cable: Diagrams Inflatable Restraint Steering Wheel Module Coil, C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7503 Inflatable Restraint Steering Wheel Module Coil, C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7504 Inflatable Restraint Steering Wheel Module Coil, C3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7505 Inflatable Restraint Steering Wheel Module Coil, C4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7506 Inflatable Restraint Steering Wheel Module Coil, C5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7507 Clockspring Assembly / Spiral Cable: Description and Operation INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL The steering wheel module coil is attached to the steering column and is located under the steering wheel. The steering wheel module coil consists of 2 or more current-carrying coils. The coils allow the rotation of the steering wheel while maintaining continuous electrical contact between the steering wheel module deployment loop and the steering wheel module. Two coil wires are used for the steering wheel module deployment loop. Additional coil wires are used for accessories that are attached to the steering wheel, depending on the vehicle model. The steering wheel module coil connector is located near the base of the steering column. The connector contains a shorting bar that shorts the steering wheel module coil deployment loop circuitry to prevent unwanted deployment of the steering wheel module when the connector is disconnected. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7508 Clockspring Assembly / Spiral Cable: Service and Repair INFLATABLE RESTRAINT STEERING WHEEL MODULE COIL REPLACEMENT REMOVAL PROCEDURE 1. Disable the SIR System. Refer to SIR Disabling and Enabling Zone 3. CAUTION: Refer to SIR Caution in Service Precautions. 2. Remove the inflatable restraint steering wheel module. 3. Remove the steering wheel nut. 4. Note the mark on the steering shaft and the steering wheel to ensure proper alignment during installation. 5. Remove the steering wheel from the steering shaft. 6. On vehicles with a tilt column, pull the tilt lever straight out from the steering column. 7. Remove the tilt lever assembly. 8. Remove 2 TORX(r) head screws (1) from the lower shroud (2). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7509 9. Remove the lower shroud (2). 10. Remove 2 TORX(r) head screws (2) from the upper shroud (1). 11. Remove the upper shroud (1). 12. Remove the wire harness straps from the steering wheel column wire harness. 13. Remove the retaining ring (3). 14. Remove the SIR coil (4) from the steering shaft. 15. If replacing, discard the SIR coil. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7510 1. To install the SIR coil, perform the following procedure: 1.1. Aim the wheels straight ahead. 1.2. Align the block tooth and the centering mark on the race and upper shaft assembly at the 12 o'clock position. 2. If centering is required, follow the instructions on the notice (1) of the coil assembly. Refer to Inflatable Restraint Steering Wheel Module Coil Centering in Steering Wheel and Column. IMPORTANT: The new SIR coil will be pre-centered. Do not remove the centering tab from the new SIR coil until the installation is complete. If the SIR coil does not come with a centering tab, you must center the SIR coil. 3. Align the SIR coil assembly (1) with the horn tower on the turn signal cancel cam assembly (2). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7511 4. Slide the new SIR coil (4) onto the steering shaft assembly (2). IMPORTANT: The new SIR coil will be pre-centered. Do not remove the centering tab from the new SIR coil until the installation is complete. 5. Firmly seat the retaining ring (3) into the groove on the steering shaft assembly (2). 6. Remove and discard the centering tab from the new SIR coil (4). 7. Install the upper shroud (1) and secure by using 2 TORX(r) head screws (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 1.5 N.m (13 lb in). 8. Install the lower shroud (2) and secure by using 2 TORX(r) head screws (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7512 9. Verify that the tabs on the lower shroud (1) engage with the tabs on the upper shroud (2). Snap the tabs together. Tighten Tighten the screws to 1.5 N.m (13 lb in). 10. On vehicles with a tilt column, align the tilt lever into the steering column. 11. Slide the tilt lever handle into the steering column until the handle locks into position. 12. Feed the wiring through the steering wheel. 13. Align the steering wheel with the mark on the steering shaft. Install the steering wheel onto the shaft. 14. Install the nut for the steering wheel. Tighten Tighten the nut to 41 N.m (30 lb ft). 15. Install the inflatable restraint steering wheel module. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag > Component Information > Diagrams > Page 7513 16. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations SIR Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7517 Locations View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7518 Lower Left Of Passenger Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7519 Impact Sensor: Diagrams Inflatable Restraint Side Impact Sensor (SIS) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7520 Inflatable Restraint Front End Discriminating Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7521 Impact Sensor: Service Precautions CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Locations > Page 7522 Impact Sensor: Description and Operation INFLATABLE FRONT END SENSOR (EFS) The front end sensor also known as the electronic frontal sensor (EFS) is equipped on some vehicles to supplement the SIR system performance. The EFS is an electronic sensor (accelerometer) and is not part of the deployment loops, but instead provides an input to the SDM. The EFS can assist in determining the severity of some frontal collisions. The SDM contains a microprocessor which performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the frontal deployment loops, deploying the frontal air bags. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 2. Remove the radiator upper air baffle and deflector. 3. Remove the orange connector position assurance (CPA) (2) from the yellow sensor harness connector (3). 4. Disconnect the harness connector from the sensor (1). 5. Remove the sensor bolts (1). 6. Remove the sensor (2) from the upper radiator core support (3). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 7525 2. Connect the harness connector (3) to the sensor (1). 3. Install the orange CPA (2) into the yellow sensor harness connector (3). 4. Position the sensor (2) horizontally on the upper radiator core support (3). NOTE: Refer to Fastener Notice in Service Precautions. 5. Point the arrow on the sensor toward the front of the vehicle. 6. Install the sensor bolts (1). Tighten Tighten the bolts to 9 N.m (80 lb in). 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. 8. Install the radiator upper air baffle and deflector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 7526 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 2 (Impala)SIR Disabling and Enabling Zone 2 (Monte Carlo). CAUTION: Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 2. Remove the center pillar lower trim. 3. Remove the connector position assurance (CPA) from the yellow 2-way harness connector on the inflatable restraint side impact sensor. 4. Disconnect the wiring harness connector from the side impact sensor. 5. Loosen the 2 fasteners (2) on the side impact sensor. 6. Remove the side impact sensor (1) from the center pillar (3). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Install the side impact sensor (1) to the center pillar (3). 3. Tighten the 2 fasteners (2) on the side impact sensor (1). 4. Connect the yellow 2-way harness connector on the side impact sensor. 5. Install the CPA to the yellow 2-way connector on the side impact sensor and tighten using only hand tools. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 7527 Tighten Tighten the fasteners to 10 N.m (89 lb in). 6. Install the center pillar lower trim. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 2 (Impala)SIR Disabling and Enabling Zone 2 (Monte Carlo). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations SIR Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Page 7535 Inflatable Restraint Side Impact Module - LF Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Page 7536 Side Air Bag: Service Precautions CAUTION: Following the deployment of a side impact air bag, replace the following parts: - The seat back trim - The seat back pad - The seat back frame Failure to do so may cause future personal injury. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Page 7537 Side Air Bag: Description and Operation SIDE SIR SYSTEM DESCRIPTION The side impact SIR system consists of the following components: - AIR BAG indicator in the instrument panel cluster (IPC) - Inflatable restraint sensing and diagnostic module (SDM) - Inflatable restraint side impact modules - LF - inflatable restraint side impact sensors (SIS) - LF The side impact modules are located in the outside portion for the front seat backs. The side impact modules consist of a housing, inflatable air bag, initiating device, and a canister of gas generating material. The initiator is part of the side impact module deployment loop. When a side impact of sufficient force occurs, the SIS detects the impact and sends a signal to the SDM. The SDM compares the signal received from the SIS to a value stored in memory. When the generated signal exceeds the stored value, the SDM will cause current to flow through the side deployment loop, deploying the inflator module. The SDM, side impact modules, and the connecting wires make up the side deployment loops. The SDM continuously monitors the side deployment loops for malfunctions and commands the IPC to turn the AIR BAG indicator ON if a fault is present. Each side impact module is equipped with a shorting bar located in the connector of the module. The shorting bar shorts the side impact module deployment loop circuitry to prevent unwanted deployment of the air bag when it is disconnected. INFLATABLE RESTRAINT SIDE IMPACT SENSOR (SIS) The side impact sensors (SIS) contains a sensing device (accelerometer) which monitors vehicle acceleration and velocity changes to detect side collisions that are severe enough to warrant side inflator module deployment. The SIS is not part of the deployment loop, but instead provides an input to the SDM. The SDM contains a microprocessor that performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the deployment loops, deploying the side air bags. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Page 7538 Side Air Bag: Service and Repair REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 7. CAUTION: Refer to SIR Caution in Service Precautions. - Refer to SIR Inflator Module Handling and Storage Caution in Service Precautions. 2. If the air bag has been deployed, replace the seat back trim, the seat back pad, and the seat back frame. CAUTION: Following the deployment of a side impact air bag, replace the following parts: The seat back trim - The seat back pad - The seat back frame Failure to do so may cause future personal injury. 1. Remove the seat back cover, as needed. The head restraint does not need to be removed. 2. Remove the driver side air bag fasteners (2). 3. Note the routing of the air bag wiring harness (4) and the retaining clip attachments within the driver seat. 4. Remove the wiring harness (4) retaining clips from the driver seat frame. 5. Gently pull the pigtail harness up into the seat cushion and the seat back, while guiding the harness through the wire triangle of the seat frame. 6. Remove the module (1) from the driver seat back frame. 7. Fully deploy the module before disposal. If the module was replaced under warranty, fully deploy and dispose of the module after the required retention period. Refer to Inflator Module Handling and Scrapping. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Side Air Bag > Component Information > Locations > Page 7539 1. Install the module (1) to the seat while guiding the pigtail harness through the trim cup. 2. Install the driver side air bag fasteners (2). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fasteners to 10 N.m (89 lb in). 3. Gently pull the wiring harness (4) down into the seat cushion while guiding the harness through the wire triangle of the seat frame. 4. Install the harness retaining clips to the seat frame. 5. Install the seat back cover. 6. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 7. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component Information > Description and Operation Malfunction Lamp / Indicator: Description and Operation AIR BAG INDICATOR The AIR BAG indicator, located in the IPC is used to notify the driver of SIR system malfunctions and to verify that the SDM is communicating with the IPC. When the ignition is turned ON, the SDM and the IPC are supplied with ignition 1 voltage. The IPC responds by flashing the AIR BAG indicator seven times. While the IPC is flashing the AIR BAG indicator, the SDM conducts tests on all SIR system components and circuits. If no malfunctions are detected, the SDM will command the IPC to turn the AIR BAG indicator OFF via Class 2 serial data. The SDM provides continuous monitoring of the inflator module circuits by conducting a sequence of checks. If a malfunction is detected, the SDM will store a diagnostic trouble code (DTC) and command the IPC to turn the AIR BAG indicator ON via Class 2 serial data. The presence of a SIR system malfunction could result in non-deployment of the inflator modules. The AIR BAG indicator will remain ON until the malfunction has been repaired. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Description and Operation Knee Diverter: Description and Operation KNEE BOLSTER The knee bolsters are designed to help restrain the lower torso of front seat occupants by absorbing the energy through the front seat occupant's upper legs. In a collision, the front seat occupant's legs may come in contact with the knee bolsters. The knee bolsters are designed to crush and deform, absorbing some of the impact and helping to reduce bodily injuries. The driver and passenger knee bolsters are located in the lower part of the instrument panel and must be inspected for damages after a collision. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Bracket Replacement - Right Knee Diverter: Service and Repair Knee Bolster Bracket Replacement - Right KNEE BOLSTER BRACKET REPLACEMENT - RIGHT REMOVAL PROCEDURE 1. Remove the instrument panel (IP) lower trim panel. 2. Reposition the right IP accessory wiring junction block. 3. Disconnect the wiring harness retainers from the knee bolster bracket. 4. Remove the bracket bolts from the IP passenger knee bolster. 5. Remove the bracket from the IP passenger knee bolster. INSTALLATION PROCEDURE 1. Align the IP passenger knee bolster bracket to the instrument carrier. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the bracket bolts to the IP passenger knee bolster at the instrument carrier in the sequence shown. Tighten Tighten the bracket bolts to 10 N.m (89 lb in). 3. Connect the wiring harness retainers to the IP passenger knee bolster bracket. 4. Install the right IP accessory wiring junction block. 5. Install the IP trim pad. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Bracket Replacement - Right > Page 7552 Knee Diverter: Service and Repair Knee Bolster Bracket Replacement - Left KNEE BOLSTER BRACKET REPLACEMENT - LEFT REMOVAL PROCEDURE 1. Remove the left instrument panel (IP) insulator. 2. Remove the steering column filler panel. 3. Remove the bracket bolts from the IP driver knee bolster at the IP lower trim panel. 4. Remove the bracket bolts from the IP knee bolster at the instrument carrier. Remove the IP knee bolster bracket. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Knee Diverter > Component Information > Service and Repair > Knee Bolster Bracket Replacement - Right > Page 7553 1. Align the knee bolster bracket to the IP. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the knee bolster bracket bolts to the instrument carrier in the sequence shown. Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Install the knee bolster bracket bolts which secure the bracket to the IP lower trim panel. Tighten Tighten the bolts to 10 N.m (89 lb in). 4. Install the steering column filler panel. 5. Install the left IP insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations SIR Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 7558 Inflatable Restraint Sensing And Diagnostic Module: Diagrams Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 7559 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 7560 Inflatable Restraint Sensing And Diagnostic Module (SDM) Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 7561 Inflatable Restraint Sensing And Diagnostic Module: Service Precautions CAUTION: - Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Locations > Page 7562 Inflatable Restraint Sensing And Diagnostic Module: Description and Operation INFLATABLE RESTRAINT SENSING AND DIAGNOSTIC MODULE (SDM) The inflatable restraint sensing and diagnostic module (SDM) is a microprocessor and the control center for the SIR system. The SDM contains internal sensors along with external sensors, if equipped, mounted at various locations, depending on vehicle. In the event of a collision, the SDM performs calculations using the signals received from the internal and external sensors, if equipped. The SDM compares the result of the calculations to values stored in memory. When these calculations exceed the stored value, the SDM will cause current to flow through the deployment loops, deploying the inflator modules. The SDM records the SIR system status when a deployment occurs and commands the IPC to turn the AIR BAG indicator ON. The SDM performs continuous diagnostic monitoring of the SIR system electrical components and circuitry when the ignition is ON. If the SDM detects a malfunction, a DTC will be stored and the SDM will turn the AIR BAG indicator ON. In the event that ignition 1 voltage is lost during a collision, the SDM maintains a 36 volt loop reserve (36 VLR) for deployment of the inflator modules. It is important to note, when disabling the SIR system for service or rescue operations, to allow the 36 VLR to dissipate, which could take up to 1 minute. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) Inflatable Restraint Sensing And Diagnostic Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module (AJ7) REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 9. CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. - Refer to SIR Caution in Service Precautions. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer. Roll back the carpet. 4. Remove the connector position assurance (CPA) from the 8-way wiring harness connector on the sensing and diagnostic module (SDM). 5. Disconnect the 8-way wiring harness connector from the SDM. 6. Remove the CPA from the 18-way wiring harness connector (2). 7. Disconnect the 18-way wiring harness connector from the SDM. 8. Remove the SDM mounting fasteners (3). 9. Remove the SDM (1) from the floor pan (2). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 7565 2. Install the SDM (1) horizontally to the floor pan (2). 3. Point the arrow on the SDM toward the front of the vehicle. 4. Install the SDM mounting fasteners (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fasteners to 10 N.m (89 lb in). 5. Install the 18-way wiring harness connector to the SDM. 6. Install the CPA to the 18-way wiring harness connector. 7. Install the 8-way wiring harness connector to the SDM. 8. Install the CPA to the 8-way wiring harness connector. 9. Install the carpet and the passenger front carpet retainer. 10. Install the passenger front seat. 11. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 9. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 7566 Inflatable Restraint Sensing And Diagnostic Module: Service and Repair Inflatable Restraint Sensing and Diagnostic Module (AK5) REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 9. CAUTION: Do not strike or jolt the inflatable restraint sensing and diagnostic module (SDM). Before applying power to the SDM, make sure that it is securely fastened with the arrow facing toward the front of the vehicle. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - If the vehicle interior is exposed to moisture and becomes soaked up to the level of the sensing and diagnostic module (SDM), the SDM and SDM harness connector must be replaced. The SDM could be activated when powered, which could cause airbag deployment and result in personal injury. - Refer to SIR Caution in Service Precautions. 2. Remove the passenger front seat. 3. Remove the passenger front carpet retainer. Roll back the carpet. 4. Remove the connector position assurance (CPA) from the wiring harness connector of the sensing and diagnostic module (SDM). 5. Disconnect the wiring harness connector from the SDM. 6. Remove the SDM mounting fasteners (3). 7. Remove the SDM (1) from the floor pan (2). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Inflatable Restraint Sensing And Diagnostic Module <--> [Air Bag Control Module] > Component Information > Service and Repair > Inflatable Restraint Sensing and Diagnostic Module (AJ7) > Page 7567 2. Install the SDM (1) horizontally to the floor pan (2). 3. Point the arrow on the SDM toward the front of the vehicle. 4. Install the SDM mounting fasteners (3). NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the fasteners to 10 N.m (89 lb in). 5. Install the wiring harness connector to the SDM. 6. Install the CPA to the SDM wiring harness connector. 7. Install the carpet and the passenger front carpet retainer. 8. Install the passenger front seat. 9. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 9. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Disabling And Enabling Zones Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7573 The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7574 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the radiator upper air baffle and deflector. 7. Remove the orange connector position assurance (CPA) (2) from the yellow sensor harness connector (3). 8. Disconnect the sensor harness connector from the sensor (1). Zone 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7575 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the side impact sensor (SIS)-LF from the center pillar. 7. Remove the connector position assurance (CPA) from the SIS-LF connector (2). 8. Disconnect the SIS-LF connector (2) from the SIS-LF (1). Zone 3 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7576 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the LH insulator panel. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Disconnect the steering wheel module coil connector. Zone 5 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7577 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the RH IP access hole cover. 7. Remove the connector position assurance (CPA) from the inflatable restraint IP module connector located to the right of the steering column. 8. Disconnect the IP module connector. Zone 7 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7578 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the fuse block access cover. 5. Remove the SIR Fuse. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the side impact module - LF connector (1) located under the driver seat. 7. Disconnect the side impact module - LF connector (1). Zone 9 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7579 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the I/P fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the LH insulator panel. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Disconnect the steering wheel module coil connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7580 9. Remove the RH I/P access hole cover. 10. Remove the CPA from the inflatable restraint I/P module connector, located at the RH side of the I/P. 11. Disconnect the I/P module connector. 12. Remove the CPA from the inflatable restraint side impact module - LF connector (1), located under the driver seat. 13. Disconnect the side impact module - LF connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7581 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition. 2. Connect the sensor harness connector (3) to the sensor (1). 3. Install the orange CPA (2) into the yellow sensor harness connector (3). 4. Install the radiator upper air baffle and deflector. 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash seven times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7582 1. Connect the SIS-LF connector (2) to the SIS-LF (1). 2. Install the CPA to the SIS-LF connector(2). 3. Install the side impact sensor (SIS)-LF into the center pillar. 4. Install the SIR Fuse. 5. Install the fuse block access cover. 6. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. 2. Connect the steering wheel module coil connector. 3. Install the CPA from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 4. Install the LH insulator panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7583 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash seven times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the IP module connector. 3. Install the CPA into the IP module connector located to the right of the steering column. 4. Install the LH insulator panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7584 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Connect the inflatable restraint side impact module - LF connector (1) located under the driver seat. 2. Install the CPA to the side impact module - LF connector (1). 3. Remove the SIR Fuse. 4. Install the fuse block access cover. 5. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 5.1. The AIR BAG indicator will flash seven times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7585 1. Remove the key from the ignition. Connect the inflatable restraint side impact module - LF connector (1), located under the driver seat. 2. Install the CPA to the side impact module - LF connector. 3. Connect the inflatable restraint I/P module connector, located at the RH side of the I/P. 4. Install the CPA to the I/P module connector. 5. Install the RH I/P access hole cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 7586 6. Connect the steering wheel module coil connector. 7. Install the CPA from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Install the LH insulator panel. 9. Install the SIR Fuse. 10. Install the LH I/P access hole cover. 11. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 11.1. The AIR BAG indicator will flash seven times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service and Repair Child Seat Tether Attachment: Service and Repair CHILD RESTRAINT TETHER ANCHOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the rear shelf trim panel. IMPORTANT: The child seat tether brackets have an anti-rotation tab. For Impala only, you must rotate this tab 90 degrees (Impala only) in order to remove or install the tether to the rear shelf. 2. Remove the screws from the child seat tether brackets. 3. For Impala only, rotate the child seat tether brackets 90 degrees in order to remove the child seat tether brackets from the slot. 4. Remove the child seat tether brackets from the rear shelf. INSTALLATION PROCEDURE 1. Position the child seat tether brackets to the slot in the rear shelf. 2. For Impala only, rotate the child seat tether brackets 90 degrees in order to install the child seat tether brackets into the slot. 3. Install the screws to the child seat tether brackets. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the screws to 20 N.m (15 lb ft). 4. Install the rear shelf trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: Customer Interest Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 7599 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues Seat Belt Buckle: All Technical Service Bulletins Restraints - Seat Belt Warning Lamp On/Buckling Issues INFORMATION Bulletin No.: 09-09-40-001A Date: February 02, 2011 Subject: Seat Belt Buckle Latching Issues and/or Seat Belt Warning Lights Illuminated Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7 X Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 09-09-40-001 (Section 09 - Restraints). This bulletin is being published to advise dealers about seat belt buckles not operating and/or seat belt warning light illumination, as well as difficulty latching and unlatching the buckle or the buckle release button sticking. Analysis of warranty data has determined that this condition may be caused by sticky beverages being spilled onto or into the seat belt buckle assembly. Foreign debris from food, candy wrappers, paper and coins can also contribute to this condition. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise the customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. Important Never insert anything other than the seat belt latch plate into the buckle assembly. Do not attempt to dig anything out of a buckle with a tool. Never try to wash out a buckle to remove a spilled liquid as this may damage the buckle. Use the following steps to determine the cause of the concern. 1. Inspect the buckle assembly with a light shining on the latch plate insertion area. Look for any debris or foreign objects in the buckle. 2. If any debris or foreign objects are observed, try to vacuum out the item. After the foreign material is removed, latch and unlatch the seat belt. If the system functions properly, do not replace the seat belt buckle assembly. 3. If the condition has not been corrected, inspect the buckle assembly for any sticky residue. If sticky residue is found, inform the customer that a substance was spilled on the seat belt buckle assembly causing the malfunction. The buckle assembly will need to be replaced at the customer's expense. 4. Refer to SI for seat belt component replacement. Important If foreign material (debris) or sticky liquids are the cause of the concern, show the customer the condition of the component (buckle assembly) and explain how it is affecting the function of the restraint system. Strongly recommend that the component be replaced at the customer's expense. Point out the fact that this is not a manufacturing defect and is not covered by the new vehicle warranty. If the customer declines to have parts replaced, the service department management must make a notation on the service record that the lack of functionality of seating position with an inoperative buckle was fully explained to the customer. The service department management must advise customer that having a non-functioning buckle in a seating position voids ability to use that seating position (no one should ride in the seat). Also make the customer aware that it may be against the law to ride in a vehicle without wearing a restraint system. 5. If further restraint diagnosis is required, refer to Seat Belt System Operational and Functional Checks in SI. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle: > 09-09-40-001A > Feb > 11 > Restraints - Seat Belt Warning Lamp On/Buckling Issues > Page 7605 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle Replacement - Left Front Seat Belt Buckle: Service and Repair Seat Belt Buckle Replacement - Left Front REMOVAL PROCEDURE 1. Position the left front seat to the forward position. 2. Remove the nut from the seat belt buckle anchor stud. 3. Disconnect the electrical connector from the seat belt buckle. 4. Remove the seat belt buckle from the left front seat. INSTALLATION PROCEDURE 1. Install the seat belt buckle to the left front seat. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle Replacement - Left Front > Page 7608 2. Install the nut to the seat belt anchor stud. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt buckle anchor nut to 42 N.m (31 lb ft). 3. Connect the electrical connector to the seat belt buckle. 4. Position the left front seat to the original position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle Replacement - Left Front > Page 7609 Seat Belt Buckle: Service and Repair Seat Belt Buckle Replacement - Center Front (Split Bench) REMOVAL PROCEDURE 1. Remove the front seat. 2. Using a 6.35 mm (1/4 in) drill bit, drill out the rivet that retains the front seat belt buckle to the rear of the front seat track. IMPORTANT: When drilling out the rivet do not enlarge the rivet hole. 3. Remove the front seat belt buckle from the front seat track. INSTALLATION PROCEDURE 1. Position the front seat belt buckle anchor to the front seat track. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle Replacement - Left Front > Page 7610 2. Install the new rivet which secures the front seat belt buckle to the rear of the front seat track. IMPORTANT: The rivet is only used for installation alignment. 3. Install the front seat. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle Replacement - Left Front > Page 7611 Seat Belt Buckle: Service and Repair Seat Belt Buckle Replacement - Right Front REMOVAL PROCEDURE 1. Position the right front seat to the forward position. 2. Remove the nut from the seat belt buckle anchor stud. 3. Disconnect the electrical connector from the seat belt buckle. 4. Remove the seat belt buckle from the right front seat. INSTALLATION PROCEDURE 1. Install the seat belt buckle to the right front seat. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle Replacement - Left Front > Page 7612 2. Install the nut to the seat belt anchor stud. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt buckle anchor nut to 42 N.m (31 lb ft). 3. Connect the electrical connector to the seat belt buckle. 4. Position the right front seat to the original position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Seat Belt Buckle Replacement - Left Front > Page 7613 Seat Belt Buckle: Service and Repair Seat Belt Replacement - Center Rear REMOVAL PROCEDURE 1. Remove the rear seat cushion. 2. Remove the nuts (1) from the center rear seat belts. 3. Remove the center rear seat belts from the vehicle. INSTALLATION PROCEDURE 1. Position the center rear seat belts to the anchor studs. 2. Install the nuts (1) to the rear seat center belts. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the nuts to 42 N.m (31 lb ft). 3. Install the rear seat cushion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations Right Side Of Driver Seat Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 7617 Seat Belt Switch-left Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Extension > Component Information > Technical Service Bulletins > Restraints - Extender Availability For Seat Belt Seat Belt Extension: Technical Service Bulletins Restraints - Extender Availability For Seat Belt INFORMATION Bulletin No.: 99-09-40-005F Date: June 23, 2010 Subject: Seat Belt Extender Availability Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2009‐2011 model years and update the Warranty Information. Please discard Corporate Bulletin Number 99-09-40-005E (Section 09 Restraints). Important: DO NOT use belt extenders when securing a child restraint. The seat and shoulder belt restraint systems used in all General Motors vehicles have sufficient belt length to accommodate most drivers and passengers. Consequently, requests for belt extensions (extenders) should be minimal. Seat belt extenders are available ONLY IN BLACK for most GM passenger cars and trucks produced in recent years. They are available in two different lengths, 23 cm (9 in) and 38 cm (15 in). They are designed to be coupled with the existing belts in each vehicle. When in use, the extender makes the belt arrangement a "custom fit" and use by anyone else or in another vehicle will lessen or nullify the protection offered by the vehicle's restraint system. For this reason, it is extremely important that the correct length extender be used for the vehicle and occupant intended. Important: Do not use an extender just to make it easier to buckle the safety belt. Use an extender only when you cannot buckle the safety belt without using an extender. Parts Information For part numbers, usage and availability of extenders, see Extension Kit in Group 14.875 (cars) or Group 16.714 (trucks) of the appropriate parts catalog. Saturn retailers should refer to the appropriate model year Parts & Illustration catalog for the vehicle. U.S. Saab dealers should contact the Parts Help line. Canadian Saab dealers should fax requests to Partech Canada. Warranty Information ^ Seat belt extenders are a NO CHARGE item to all GM customers who request them for their specific vehicles. ^ Dealers should not be charging part costs since these extenders are supplied by GM to the dealers. ^ Dealers should not be charging labor costs since the extender can be customer installed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Shoulder Belt Guide Adjuster Replacement - Front Seat Belt Guide Track: Service and Repair Shoulder Belt Guide Adjuster Replacement - Front REMOVAL PROCEDURE 1. Remove the center pillar upper trim panel. 2. Remove the shoulder belt guide adjuster bracket bolts. 3. Remove the shoulder belt guide belt adjuster bracket from the center pillar. INSTALLATION PROCEDURE 1. Position the shoulder belt guide adjuster bracket to the center pillar. IMPORTANT: Verify that the release lever is at the top of the adjuster bracket in the full up position. 2. Install the bracket bolts to the shoulder belt guide adjuster. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bracket bolts to 42 N.m 31 lb ft). 3. Install the trim panel for the upper center pillar. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Shoulder Belt Guide Adjuster Replacement - Front > Page 7626 Seat Belt Guide Track: Service and Repair Guide Replacement - Rear Seat Shoulder Belt TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE 1. Push back the rear seat back. 2. Use J 38778 in order to remove the push-pin retainer from the child shoulder belt guide rerouter. 3. Remove the child shoulder belt guide rerouter from the rear quarter lower trim panel. INSTALLATION PROCEDURE 1. Push back the rear seat back. 2. Align the child shoulder belt guide rerouter to the rear quarter lower trim panel. 3. Install the push-pin retainer to the child shoulder belt guide rerouter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Left Front Seat Belt Retractor: Service and Repair Seat Belt Retractor Replacement - Left Front REMOVAL PROCEDURE 1. Remove the seat belt anchor nut from the seat stud. 2. Open the seat belt guide loop cover. 3. Remove the nut from seat belt guide loop. 4. Remove the seat belt guide loop from the guide adjuster bracket. 5. Remove the center pillar lower trim. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Left Front > Page 7631 6. Remove the bolts from the seat belt intermediate guide. 7. Remove the seat belt intermediate guide from the center pillar. 8. Remove the seat belt retractor bolt. 9. Remove the seat belt retractor from the center pillar. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Left Front > Page 7632 1. Install the seat belt retractor into the T-slot in the center pillar. 2. Install the seat belt retractor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt retractor bolt to 68 N.m (50 lb ft). 3. Install the seat belt intermediate guide to the center pillar. 4. Install the seat belt intermediate guide bolts. Tighten Tighten the seat belt intermediate guide bolts to 10 N.m (89 lb in). 5. Install the center pillar lower trim. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Left Front > Page 7633 6. Position the seat belt guide loop to the guide adjuster bracket. 7. Install the nut to the seat belt guide loop. Tighten Tighten the nut to 42 N.m (31 lb ft). 8. Close the seat belt guide loop cover. 9. Install the seat belt anchor nut to the seat stud. Tighten Tighten the nut to 42 N.m (31 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Left Front > Page 7634 Seat Belt Retractor: Service and Repair Seat Belt Retractor Replacement - Right Front REMOVAL PROCEDURE 1. Remove the seat belt anchor nut from the seat stud. 2. Open the seat belt guide loop cover. 3. Remove the nut from guide loop. 4. Remove the seat belt guide loop from the guide adjuster bracket. 5. Remove the center pillar lower trim. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Left Front > Page 7635 6. Remove the bolts from the seat belt intermediate guide. 7. Remove the seat belt intermediate guide from the center pillar. 8. Remove the seat belt retractor bolt. 9. Remove the seat belt retractor from the center pillar. INSTALLATION PROCEDURE 1. Install the seat belt retractor into the T-slot in the center pillar. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Left Front > Page 7636 2. Install the seat belt retractor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the seat belt retractor bolt to 68 N.m (50 lb ft). 3. Install the seat belt intermediate guide to the center pillar. 4. Install the seat belt intermediate guide bolts. Tighten Tighten the seat belt intermediate guide bolts to 10 N.m (89 lb in). 5. Install the center pillar lower trim. 6. Position the seat belt guide loop to the guide adjuster bracket. 7. Install the nut to the seat belt guide loop. Tighten Tighten the seat belt guide loop nut to 42 N.m (31 lb ft). 8. Close the seat belt guide loop cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Left Front > Page 7637 9. Install the seat belt anchor nut to the seat stud. Tighten Tighten the nut to 42 N.m (31 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Left Front > Page 7638 Seat Belt Retractor: Service and Repair Seat Belt Retractor Replacement - Rear REMOVAL PROCEDURE 1. Remove the rear shelf trim panel. 2. Remove the rear quarter lower trim panel. 3. Remove the rear seat retractor seat belt bolt. 4. Remove the rear seat belt anchor bolt. 5. Remove the rear seat belt retractor from the vehicle. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Left Front > Page 7639 1. Install the rear seat retractor side belt to the vehicle. IMPORTANT: The anti-rotation tab must be in the proper hole in the rear shelf. 2. Install the rear seat belt retractor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the rear seat belt retractor bolt to 68 N.m (50 lb ft). 3. Install the rear seat belt anchor bolt. Tighten Tighten the rear seat belt anchor bolt to 42 N.m (31 lb ft). 4. Install the rear quarter lower trim panel. 5. Install the rear shelf trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Seat Belt Retractor Replacement - Left Front > Page 7640 Seat Belt Retractor: Service and Repair Seat Belt Retractor Replacement - Center Rear REMOVAL PROCEDURE 1. Remove the rear shelf trim panel. 2. Remove the rear seat retractor seat belt bolt. 3. Remove the rear seat belt retractor from the vehicle. INSTALLATION PROCEDURE 1. Position the center, rear seat belt retractor on the rear shelf. IMPORTANT: The anti-rotation tab must be in the proper hole in the rear shelf. 2. Install the rear seat belt retractor bolt. NOTE: Refer to Fastener Notice in Service Precautions. Tighten Tighten the bolt to 68 N.m (50 lb ft). 3. Install the rear shelf trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations Impact Sensor: Locations SIR Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7645 Locations View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7646 Lower Left Of Passenger Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7647 Impact Sensor: Diagrams Inflatable Restraint Side Impact Sensor (SIS) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7648 Inflatable Restraint Front End Discriminating Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7649 Impact Sensor: Service Precautions CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Locations > Page 7650 Impact Sensor: Description and Operation INFLATABLE FRONT END SENSOR (EFS) The front end sensor also known as the electronic frontal sensor (EFS) is equipped on some vehicles to supplement the SIR system performance. The EFS is an electronic sensor (accelerometer) and is not part of the deployment loops, but instead provides an input to the SDM. The EFS can assist in determining the severity of some frontal collisions. The SDM contains a microprocessor which performs calculations using the measured accelerations and compares these calculations to a value stored in memory. When the generated calculations exceed the stored value, the SDM will cause current to flow through the frontal deployment loops, deploying the frontal air bags. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement Impact Sensor: Service and Repair Inflatable Restraint Front End Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 1. CAUTION: Do not strike or jolt the inflatable restraint front end sensor. Before applying power to the front end sensor make sure that it is securely fastened. Failure to observe the correct installation procedure could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 2. Remove the radiator upper air baffle and deflector. 3. Remove the orange connector position assurance (CPA) (2) from the yellow sensor harness connector (3). 4. Disconnect the harness connector from the sensor (1). 5. Remove the sensor bolts (1). 6. Remove the sensor (2) from the upper radiator core support (3). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 7653 2. Connect the harness connector (3) to the sensor (1). 3. Install the orange CPA (2) into the yellow sensor harness connector (3). 4. Position the sensor (2) horizontally on the upper radiator core support (3). NOTE: Refer to Fastener Notice in Service Precautions. 5. Point the arrow on the sensor toward the front of the vehicle. 6. Install the sensor bolts (1). Tighten Tighten the bolts to 9 N.m (80 lb in). 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 1. 8. Install the radiator upper air baffle and deflector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 7654 Impact Sensor: Service and Repair Inflatable Restraint Side Impact Sensor Replacement REMOVAL PROCEDURE 1. Disable the SIR system. Refer to SIR Disabling and Enabling Zone 2 (Impala)SIR Disabling and Enabling Zone 2 (Monte Carlo). CAUTION: Do not strike or jolt the inflatable restraint side impact sensor (SIS). Before applying power to the SIS make sure that it is securely fastened. Failure to observe the correct installation procedures could cause SIR deployment, personal injury, or unnecessary SIR system repairs. - Refer to SIR Caution in Service Precautions. 2. Remove the center pillar lower trim. 3. Remove the connector position assurance (CPA) from the yellow 2-way harness connector on the inflatable restraint side impact sensor. 4. Disconnect the wiring harness connector from the side impact sensor. 5. Loosen the 2 fasteners (2) on the side impact sensor. 6. Remove the side impact sensor (1) from the center pillar (3). INSTALLATION PROCEDURE 1. Remove any dirt, grease, or other impurities from the mounting surface. 2. Install the side impact sensor (1) to the center pillar (3). 3. Tighten the 2 fasteners (2) on the side impact sensor (1). 4. Connect the yellow 2-way harness connector on the side impact sensor. 5. Install the CPA to the yellow 2-way connector on the side impact sensor and tighten using only hand tools. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor > Component Information > Service and Repair > Inflatable Restraint Front End Sensor Replacement > Page 7655 Tighten Tighten the fasteners to 10 N.m (89 lb in). 6. Install the center pillar lower trim. 7. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 2 (Impala)SIR Disabling and Enabling Zone 2 (Monte Carlo). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations Right Side Of Driver Seat Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Locations > Page 7659 Seat Belt Switch-left Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Occupant Sensor > Component Information > Technical Service Bulletins > Restraints - Passenger Presence System Information Seat Occupant Sensor: Technical Service Bulletins Restraints - Passenger Presence System Information INFORMATION Bulletin No.: 06-08-50-009F Date: December 23, 2010 Subject: Information on Passenger Presence Sensing System (PPS or PSS) Concerns With Custom Upholstery, Accessory Seat Heaters or Other Comfort Enhancing Devices Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Passenger Presence Sensing System Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 06-08-50-009E (Section 08 - Body and Accessories). Concerns About Safety and Alterations to the Front Passenger Seat Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE THE SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER THE SEAT COVERS OR SEAT-RELATED EQUIPMENT. ANY ALTERATIONS TO SEAT COVERS OR GM ACCESSORIES DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. The front passenger seat in many GM vehicles is equipped with a passenger sensing system that will turn off the right front passenger's frontal airbag under certain conditions, such as when an infant or child seat is present. In some vehicles, the passenger sensing system will also turn off the right front passenger's seat mounted side impact airbag. For the system to function properly, sensors are used in the seat to detect the presence of a properly-seated occupant. The passenger sensing system may not operate properly if the original seat trim is replaced (1) by non-GM covers, upholstery or trim, or (2) by GM covers, upholstery or trim designed for a different vehicle or (3) by GM covers, upholstery or trim that has been altered by a trim shop, or (4) if any object, such as an aftermarket seat heater or a comfort enhancing pad or device is installed under the seat fabric or between the occupant and the seat fabric. Aftermarket Seat Heaters, Custom Upholstery, and Comfort Enhancing Pads or Devices Important ON A GM VEHICLE EQUIPPED WITH A PASSENGER SENSING SYSTEM, USE ONLY SEAT COVERS AND OTHER SEAT-RELATED EQUIPMENT RELEASED AS GM ACCESSORIES FOR THAT VEHICLE. DO NOT USE ANY OTHER TYPE OF SEAT COVERS OR SEAT-RELATED EQUIPMENT, OR GM ACCESSORIES RELEASED FOR OTHER VEHICLE APPLICATIONS. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER SEAT ACCESSORIES, INCLUDING ANY WARRANTY REPAIRS MADE NECESSARY BY SUCH USE. Many types of aftermarket accessories are available to customers, upfitting shops, and dealers. Some of these devices sit on top of, or are Velcro(R) strapped to the seat while others such as seat heaters are installed under the seat fabric. Additionally, seat covers made of leather or other materials may have different padding thickness installed that could prevent the Passenger Sensing System from functioning properly. Never alter the vehicle seats. Never add pads or other devices to the seat cushion, as this may interfere with the operation of the Passenger Sensing System and either prevent proper deployment of the passenger airbag or prevent proper suppression of the passenger air bag. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7669 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7670 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7671 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7672 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7673 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7674 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7675 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7676 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7677 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7678 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7679 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7680 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7681 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7682 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7683 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7684 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7685 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7686 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7687 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7688 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7689 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7690 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7691 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7692 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7693 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7694 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7695 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7696 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7697 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7698 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7699 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7700 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7701 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7702 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7703 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7704 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7705 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7706 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7707 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7708 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7709 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7710 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7711 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7712 Accessory Delay Module: Electrical Diagrams Retained Accessory Power (RAP) Diagram 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 7713 Retained Accessory Power (RAP) Diagram 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 7714 Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) Retained accessory power (RAP) is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its shut-off limit. The modules listed below all receive a RAP message from the body control module (BCM) over the serial data circuits. The BCM monitors the ignition switch position, battery condition and passenger compartment door status to determine whether RAP should be initiated. The BCM then sends a message to the listed modules telling them that they are in RAP power mode. The modules then support the operation of the systems under their control as required by their RAP power mode strategy. RAP will end when 1 of the following conditions are met: The BCM receives an input, as a hard wired input from the door switches, indicating the opening of a passenger compartment door. - The BCM receives a message from its internal timer indicating the end of the RAP period after 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. - The transition from OFF to RUN/ON or ACC of the ignition switch. The BCM then sends a serial data message to the listed devices ending the RAP function. The devices receiving serial data messages for RAP functions are: Auxiliary power drop connector - Driver information center (DIC) - Instrument panel cluster (IPC) - Radio - Remote CD player, if equipped - Vehicle interface unit (VIU), if equipped RELAY CONTROL OF RETAINED ACCESSORY POWER (RAP) RAP is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its shut-off limit. The BCM closes the RAP relay in either the RAP function as described above or if the BCM detects a RUN/ON or accessory power mode. This provides power for the following: The power windows - The sunroof control module, if equipped The BCM opens the RAP relay to end the RAP function when it ends the RAP function as outlined in the previous text. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point DIAGNOSTIC STARTING POINT - ACCESSORY DELAY MODULE Begin the system diagnosis with a Diagnostic System Check - Accessory Delay Module. The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check DIAGNOSTIC SYSTEM CHECK - ACCESSORY DELAY MODULE TEST DESCRIPTION The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. The presence of DTCs which begin with U indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. TEST Steps 1 - 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7717 Steps 4 - 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7718 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms SYMPTOMS - ACCESSORY DELAY MODULE IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory Power (RAP) Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which may affect the operation of the retained accessory power system. - Inspect the easily accessible or visible system components for obvious damage or conditions which may cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7719 Steps 1 - 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7720 Steps 10 - 11 Steps 1 - 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7721 Steps 4 - 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7722 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Software Part Number: Part number of component program or the ECU. Used to determine applicability to vehicle RPO content. Accessory Switch: Input from ignition switch Accessory circuit. Used to determine power mode. Hot in ACCESSORY and RUN. Driver Door Open Sw.: Input from the driver door indicating door status (Open-Closed). Door Ajar Switches: Input showing state of the passenger door(s). Doors Battery Fd: Indicates completion of the power circuit for the door control functions. Doors System Gnd: Indicates the completion state of the ground circuit for the door functions. Electronics Battery Fd: Data indicates the voltage detected by the control module on the power circuit for the module internal devices. Electronics Battery Fd: Input indicates the completion state of the power circuit for the module internal devices. Electronics System Gnd: Indicates the completion state of the ground circuit for the module internal devices. Ignition 0: Input to the control module from the ignition switch indicating the Ignition 0 position. Switch closed (HOT) in ignition switch positions Unlock, Accessory, Run, Crank. Ignition 1: Input to the control module from the ignition switch indicating the Ignition 1 position. Switch closed (HOT) in ignition switch positions Run, Crank. Inadvertent Power Output: Input indicating the sensed state of the inadvertent power request circuit. Inadvertent Power Relay: Output indicating the state as commanded by the control module. Lamp Request: Input telling the control module to initiate inadvertent power management. Load Management Status: Output indicating the power mode commanded. Loads Battery Fd: Indicates the completion state of the supply circuit for the high current loads. Loads System Gnd: Indicates completion state of the ground circuit for the high current loads. Pass Door Jamb Sw.: Input showing the state of the front passenger door. RAP Relay: Output indicates state that the control module has commanded. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 7723 Scan Tool Data List Scan Tool Output Controls Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Technical Service Bulletins > Customer Interest for Antenna Control Module: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception Antenna Control Module: Customer Interest Audio System - Static/Poor Radio Reception Bulletin No.: 05-08-44-008A Date: June 17, 2005 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Static, Poor and/or No AM/FM Radio Reception In Police Package Equipped Vehicles (Replace Radio Antenna Module) Models: 2004-2005 Chevrolet Impala Built After VIN Breakpoint 49302036 with Police Package (RPO 9C1) Supercede: This bulletin is being revised to include Diagnostic and Repair Information, remove an RPO code and include a VIN breakpoint. Please discard Corporate Bulletin Number 05-08-44-008 (Section 08 - Body and Accessories). Condition Some customers may comment that certain police package vehicles equipped with radio communication equipment may experience poor AM/FM radio reception, no radio reception and/or static through the radio system. Cause Police package vehicles radio communication equipment may overload the radio AM/FM radio antenna module. Diagnosis To ensure the radio antenna module is the cause of the poor reception, refer to Radio Poor Reception (SI Document ID # 782713). Correction If diagnosis leads to a suspect radio antenna module, replace the Radio Antenna Module. Refer to Antenna Module Replacement (SI Document ID # 1515377). Dealer Action Contact customers that were told they would be notified when this repair became available. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Technical Service Bulletins > Customer Interest for Antenna Control Module: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception > Page 7733 Parts Parts will be available for dealer ordering on June 20, 2005. Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna Control Module: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception Antenna Control Module: All Technical Service Bulletins Audio System - Static/Poor Radio Reception Bulletin No.: 05-08-44-008A Date: June 17, 2005 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Static, Poor and/or No AM/FM Radio Reception In Police Package Equipped Vehicles (Replace Radio Antenna Module) Models: 2004-2005 Chevrolet Impala Built After VIN Breakpoint 49302036 with Police Package (RPO 9C1) Supercede: This bulletin is being revised to include Diagnostic and Repair Information, remove an RPO code and include a VIN breakpoint. Please discard Corporate Bulletin Number 05-08-44-008 (Section 08 - Body and Accessories). Condition Some customers may comment that certain police package vehicles equipped with radio communication equipment may experience poor AM/FM radio reception, no radio reception and/or static through the radio system. Cause Police package vehicles radio communication equipment may overload the radio AM/FM radio antenna module. Diagnosis To ensure the radio antenna module is the cause of the poor reception, refer to Radio Poor Reception (SI Document ID # 782713). Correction If diagnosis leads to a suspect radio antenna module, replace the Radio Antenna Module. Refer to Antenna Module Replacement (SI Document ID # 1515377). Dealer Action Contact customers that were told they would be notified when this repair became available. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna Control Module: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception > Page 7739 Parts Parts will be available for dealer ordering on June 20, 2005. Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Technical Service Bulletins > Page 7740 Antenna Control Module: Locations Left Side Of Rear Window Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Technical Service Bulletins > Page 7741 Left Side Of Rear Window Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Technical Service Bulletins > Page 7742 Radio Antenna Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Technical Service Bulletins > Page 7743 Antenna Control Module: Service and Repair ANTENNA MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the upper trim panel from the left rear quarter. 2. Disconnect the antenna amplifier electrical connector and the antenna coaxial cable. The antenna coaxial cable uses a sliding snap-lock. Pull the lock in order to remove the antenna coaxial cable. 3. Detach the black antenna leads from the glass. The upper lead is held to the body metal with a wiring clip. Carefully pry the clip out of the metal. 4. Remove the antenna amplifier bolt. 5. Remove the antenna amplifier. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Position the antenna amplifier to the inner upper panel of the left rear window. Install the antenna amplifier bolt. Tighten Tighten the bolt to 3 N.m (27 lb in). IMPORTANT: The antenna coaxial cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. 2. Connect the antenna amplifier electrical connectors: 2.1. Position the antenna coaxial cable behind the sliding lock feature. 2.2. Install the antenna coaxial cable to the sliding lock feature. IMPORTANT: If the wiring clip is faulty, replace the wiring clip prior to installation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Control Module > Component Information > Technical Service Bulletins > Page 7744 3. Install the antenna leads to the rear window terminals. Push the wiring clip on the upper lead into the hex hole in the metal. 4. Install the upper trim panel at the left rear quarter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > Customer Interest: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: Customer Interest Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 7758 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna, Navigation: > 00-08-46-003B > Feb > 05 > Instruments - GPS System Performance Degradation Antenna, Navigation: All Technical Service Bulletins Instruments - GPS System Performance Degradation Info - Global Position Sensor (GPS) Performance Degradation # 00-08-46-003B - (Feb 9, 2005) Models: 1996-2005 Passenger Cars and Trucks 2002-2005 Saturn Vehicles with Navigation Systems and/or OnStar(R) This bulletin is being revised to include additional information. Please discard Corporate Bulletin Number 00-08-46-003A (Section 08 - Body and Accessories). Navigation and OnStar(R) systems require a GPS antenna in order to function properly. This antenna may be located inside the vehicle. If the GPS antenna is located inside the vehicle, performance of the system may be compromised by window tinting film. If the GPS system performance is in question and the vehicle has window tinting, a quick diagnostic check can be made by temporarily moving the GPS antenna to an external vehicle surface, such as the decklid or roof. If the GPS function of the navigation or On Star(R) system operates normally with the antenna relocated the repair would not be considered a warranty repair. The subsequent repair procedure or GPS placement would be up to the customer. Some vehicles have the GPS antenna located on the rear window shelf Objects placed on the rear window shelf such as tissue boxes, books, dolls, etc,, also have the potential to interfere with GPS performance. Warranty Information Repairs made to the vehicle navigation and/or OnStar(R) system, which are the result of window tinting, are not considered warranty repairs. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Navigation: All Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Navigation > Component Information > Technical Service Bulletins > All Other Service Bulletins for Antenna, Navigation: > 00-08-46-002A > Apr > 05 > OnStar(R) - Cellular Antenna Replacement Parts > Page 7768 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Antenna, Phone: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Phone > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 7773 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 7778 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner Global Positioning System Antenna: Service and Repair Coupling Replacement - Antenna Inner COUPLING REPLACEMENT - ANTENNA INNER REMOVAL PROCEDURE IMPORTANT: Use adhesion promoter to ensure adequate bonding of the coupling. - To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60°F) during installation. Allow 6 to 8 hours, at 15°C (60°F), for the adhesive to cure after installation. Otherwise, the new couplings may not adhere. - Do not attempt to reinstall the original cellular antenna exterior coupling or inner coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Disconnect the coaxial cable from the mobile communication antenna inner coupling. NOTE: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. 2. Use a small wide-bladed plastic tool to cut the double back tape material while lifting up on the inner antenna coupling (2). INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 7781 1. Clean the inside of the back glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. 3. Apply Glass Adhesion Promoter GM P/N 12378555 (Canadian P/N 88901239), to the back glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. IMPORTANT: The IF connections for the inner antenna coupling should run parallel to the defogger gridline. - Align the inner and outer antenna couplings. - Do not touch the adhesive backing on the antenna coupling. 1. If the exterior coupling is not installed, mark the inner antenna coupling location (A) 92 mm (3.75 in) and (B) 80 mm (3.25 in) with a grease pencil on the exterior surface of the rear window. 2. Remove the protective film from the adhesive backing on the inner antenna coupling. 3. Align the inner antenna coupling to the locating marks on the back glass or the exterior coupling. 4. Press firmly on all 4 corners and on the center of the antenna inner coupling (2) in order to ensure proper adhesion to the back glass (4). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 7782 Hold pressure on the inner coupling (2) for 10-30 seconds. 5. Ensure there are not any gaps between the couplings (5, 2) and the back glass (4). 6. Connect the coaxial cable to the inner coupling. 7. Keep the vehicle dry. Allow 6-8 hours, at 15°C (60°F), for the adhesive to cure after installation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 7783 Global Positioning System Antenna: Service and Repair Coupling Replacement - Antenna Outer COUPLING REPLACEMENT - ANTENNA OUTER REMOVAL PROCEDURE IMPORTANT: Use adhesion promoter to ensure adequate bonding of the coupling. - To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60°F) during installation. Allow 6 to 8 hours, at 15°C (60°F), for the adhesive to cure after installation. Otherwise, the new couplings may not adhere. - Do not attempt to reinstall the original cellular antenna exterior coupling or inner coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Install the inner coupling first if both the inner and the outer coupling are to be replaced. NOTE: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. 2. Use a small wide-bladed plastic tool to cut the double back tape material while lifting up on the outer antenna coupling (5). INSTALLATION PROCEDURE 1. Clean back glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. 3. Apply Glass Adhesion Promoter GM P/N 12378555 (Canadian P/N 88901239) to the back glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. IMPORTANT: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 7784 - Align the inner and outer antenna couplings. - Do not touch the adhesive backing on the antenna coupling. 1. Remove the protective film from the adhesive backing on the outer antenna coupling. 2. Align the outer antenna coupling to the inner antenna coupling. 3. Press firmly on all 4 corners and on the center of the antenna outer coupling (5) in order to ensure proper adhesion to the back glass (4). Hold pressure on the outer coupling (5) for 10-30 seconds. 4. Ensure that no gaps occur between the couplings (5, 2) and the back glass (4). 5. Keep the vehicle dry. Allow 6-8 hours, at 15°C (60°F), for the adhesive to cure after installation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 7785 Global Positioning System Antenna: Service and Repair Navigation Antenna Replacement NAVIGATION ANTENNA REPLACEMENT REMOVAL PROCEDURE 1. Remove the rear shelf trim panel. 2. Adjust the acoustical barrier for access. 3. Remove the antenna assembly tape from the rear shelf. 4. Remove the global positioning system (GPS) antenna from the rear shelf using a small wide-bladed plastic tool in order to release the adhesive. 5. Disconnect the GPS antenna cable connector. 6. Clean the adhesive residue from the rear shelf using a razor blade and isopropyl alcohol pad and a clean lint-free cloth. INSTALLATION PROCEDURE 1. Clean the surface of the rear shelf in the (GPS) antenna mounting location, using an isopropyl alcohol pad and a clean lint-free cloth. 2. Connect the GPS antenna cable connector. IMPORTANT: Do not touch the adhesive backing. 3. Remove the protective backing from the adhesive on the GPS antenna. 4. Install the GPS antenna to the rear shelf surface. Press the GPS antenna into place until fully seated for approximately 30 seconds. 5. Secure the antenna assembly to the rear shelf with tape. 6. Install the acoustical barrier. 7. Install the rear shelf trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Coaxial Cable Replacement - Digital Radio Antenna Cable: Service and Repair Coaxial Cable Replacement - Digital Radio COAXIAL CABLE REPLACEMENT - DIGITAL RADIO REMOVAL PROCEDURE 1. Remove the right rear upper quarter trim panel. 2. Lower the rear of the headliner for access to the antenna/cable attachment. Refer to Headliner Replacement (Impala)Headliner Replacement (Monte Carlo) in Interior Trim. 3. Adjust the antenna cable mastic patch/tape at the roof. 4. Disconnect the antenna cable from the antenna base cable connector. 5. Remove the antenna cable retainer (3) from the rear header (2). 6. Remove the antenna cable from the dome lamp harness clips. 7. Remove the antenna cable from between the dome lamp harness and the upper quarter panel. 8. Attach a piece of wire or string to the end of the antenna cable. 9. Route the antenna cable through the rear shelf and along the rear wheel house. 10. Adjust the right rear compartment trim panel. 11. Disconnect the antenna cable from the digital radio receiver. 12. Remove the antenna cable retainers from the receiver bracket. 13. Remove the wire or string from the antenna cable. 14. Remove the antenna cable. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Coaxial Cable Replacement - Digital Radio > Page 7791 1. Install the antenna cable retainers to the receiver bracket. 2. Connect the antenna cable to the digital radio receiver. 3. Attach the wire or string used in the removal procedure to the cable being installed. 4. Carefully pull the antenna cable through the rear shelf into the passenger compartment. 5. Install the right rear compartment trim panel. 6. Remove the wire or string from the antenna cable. 7. Route the antenna cable between the dome lamp harness and the upper quarter panel. 8. Install the antenna cable to the dome lamp harness clips. 9. Install the antenna cable retainer (3) to the rear header (2). 10. Connect the antenna cable to the antenna base cable connector. 11. Install the antenna cable mastic patch/tape at the roof. 12. Install the rear of the headliner. 13. Install the right rear upper quarter trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Coaxial Cable Replacement - Digital Radio > Page 7792 Antenna Cable: Service and Repair Antenna Extension Cable Replacement ANTENNA EXTENSION CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the left carpet retainer. 2. Adjust the carpet for access. 3. Disconnect the antenna extension cable from the antenna cable. 4. Remove the left instrument panel insulator. 5. Adjust the radio for access. Disconnect the antenna extension cable from the radio. Refer to Radio Replacement. 6. Cut off the visible ends of the antenna extension cable. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Coaxial Cable Replacement - Digital Radio > Page 7793 1. Route the antenna extension cable. Secure the cable. 2. Connect the antenna extension cable to the radio. Install the radio. IMPORTANT: The antenna cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. 3. Connect the antenna extension cable from the radio to the antenna cable near the kick panel: 3.1. Position the antenna extension cable behind the sliding lock feature. 3.2. Install the antenna extension cable to the sliding lock feature. 4. Install the left instrument panel insulator. 5. Install the carpet. 6. Install the left carpet retainer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Coaxial Cable Replacement - Digital Radio > Page 7794 Antenna Cable: Service and Repair Antenna Cable Replacement ANTENNA CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the rear upper quarter trim panel. 2. Disconnect the antenna cable from the radio antenna module. 3. Remove the rear seat cushion. 4. Remove the rear seat back. 5. Remove the left carpet retainers. 6. Remove the lower center pillar trim panel. 7. Adjust the carpet for access to the antenna cable as required. 8. Disconnect the antenna cable from the antenna extension cable. 9. Cut off the visible end of the antenna cable from the wiring harness in the following locations: - The kick panel area - The rear shelf area INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Service and Repair > Coaxial Cable Replacement - Digital Radio > Page 7795 1. Install the antenna cable to the vehicle. Use electrical tape in order to secure the antenna extension cable to the top of the wiring harness. Secure the cable to the harness at least every 150 mm (6 in). IMPORTANT: The antenna cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. 2. Connect the antenna extension cable from the radio to the antenna cable near the kick panel: 2.1. Position the antenna extension cable behind the sliding lock feature. 2.2. Install the antenna extension cable to the sliding lock feature. 3. Install the carpet. 4. Install the lower center pillar trim panel. 5. Install the left carpet retainers. 6. Install the rear seat back. 7. Install the rear seat cushion. IMPORTANT: The antenna cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. 8. Connect the antenna cable to the radio antenna module: 8.1. Position the antenna cable behind the sliding lock feature. 8.2. Install the antenna cable to the sliding lock feature. 9. Install the rear upper quarter trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Diagrams Remote Control Door Lock Receiver (RCDLR) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Receiver > Component Information > Diagrams > Page 7801 Keyless Entry Receiver: Service and Repair REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel (IP) upper trim panel. 2. Disengage the receiver retainers from the IP upper trim pad. 3. Disconnect the receiver electrical connector. 4. Remove the receiver. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Engage the receiver retainers to the IP upper trim pad. 3. Install the IP upper trim panel. 4. If a new remote control door lock receiver is being installed, synchronize the transmitter. Refer to Transmitter Synchronization. See: Testing and Inspection/Programming and Relearning 5. If a new remote control door lock receiver is being installed, program the transmitter. Refer to Transmitter Programming. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT Under normal use, the battery in the remote control door lock transmitter will last about 2 years. The battery is weak if the transmitter does not work at the normal range in any location. If you have to get close to the vehicle before the transmitter works, change the battery. Removal Procedure 1. Insert a dime or a flat-bladed tool into the slot on the side of the transmitter in order to disassemble the transmitter. 2. Twist the dime or tool in order to separate the halves. 3. Remove the battery from the transmitter. Installation Procedure 1. Install the battery into the transmitter. 2. Reassemble the transmitter. 3. Ensure that the halves snap together tightly in order to prevent water intrusion. 4. Test for proper transmitter operation. Refer to Transmitter Programming. 5. Synchronize the transmitter, as needed. Refer to Transmitter Synchronization. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams Passlock Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch > Component Information > Diagrams > Page 7809 Lock Cylinder Switch: Description and Operation PASSLOCK(TM) SENSOR The Passlock(TM) sensor contains 2 hall effect sensors. The tamper hall effect sensor is on the top. The security hall effect sensor is under the tamper hall effect sensor. Both of the hall effect sensors monitor the magnet of the lock cylinder through an opening. The tamper hall effect sensor is physically placed on top of the security hall effect sensor. This arrangement enables the tamper hall effect sensor to engage first if an intruder attempts to bypass the Passlock(TM) sensor by placing a large magnet around that area of the steering column. There is a tamper resistor inside the Passlock(TM) sensor in order to help prevent tamper to the system. Passlock(TM) equipped vehicles have a selection of 10 different security resistors ranging from 0.5K ohms up to 13.6K ohms. Installing one of the security resistors inside the Passlock(TM) sensor will generate a unique Passlock(TM) code. All 10 combinations of the Passlock(TM) sensor have the same part number. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 05-08-46-010 > Dec > 05 > OnStar(R) - Microphone Inoperative Cellular Phone Microphone: Customer Interest OnStar(R) - Microphone Inoperative Bulletin No.: 05-08-46-010 Date: December 22, 2005 TECHNICAL Subject: OnStar(R) Microphone Inoperative (Replace OnStar(R) Microphone) Models: 2002-2004 Buick Regal 2002-2005 Buick Century 2003-2005 Buick LeSabre 2005 Buick Allure (Canada Only), LaCrosse 2006 Buick Lucerne 2002-2005 Chevrolet Impala, Monte Carlo 2004-2006 Chevrolet Colorado 2004-2006 GMC Canyon 2004-2005 Pontiac Grand Prix 2003-2006 Saturn ION Condition Some customers may comment of an inoperative OnStar(R) microphone. Correction If normal diagnostic procedures lead to a failed OnStar(R) microphone, technicians are to replace only the microphone and not the entire rearview mirror assembly. Prior to the release of this bulletin it was necessary to replace the entire rearview mirror assembly if the OnStar(R) microphone had failed. Refer to the OnStar Microphone Replacement procedure in the Cellular Communication sub-section of SI. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Customer Interest for Cellular Phone Microphone: > 05-08-46-010 > Dec > 05 > OnStar(R) - Microphone Inoperative > Page 7819 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 05-08-46-010 > Dec > 05 > OnStar(R) - Microphone Inoperative Cellular Phone Microphone: All Technical Service Bulletins OnStar(R) - Microphone Inoperative Bulletin No.: 05-08-46-010 Date: December 22, 2005 TECHNICAL Subject: OnStar(R) Microphone Inoperative (Replace OnStar(R) Microphone) Models: 2002-2004 Buick Regal 2002-2005 Buick Century 2003-2005 Buick LeSabre 2005 Buick Allure (Canada Only), LaCrosse 2006 Buick Lucerne 2002-2005 Chevrolet Impala, Monte Carlo 2004-2006 Chevrolet Colorado 2004-2006 GMC Canyon 2004-2005 Pontiac Grand Prix 2003-2006 Saturn ION Condition Some customers may comment of an inoperative OnStar(R) microphone. Correction If normal diagnostic procedures lead to a failed OnStar(R) microphone, technicians are to replace only the microphone and not the entire rearview mirror assembly. Prior to the release of this bulletin it was necessary to replace the entire rearview mirror assembly if the OnStar(R) microphone had failed. Refer to the OnStar Microphone Replacement procedure in the Cellular Communication sub-section of SI. Parts Information Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cellular Phone Microphone: > 05-08-46-010 > Dec > 05 > OnStar(R) - Microphone Inoperative > Page 7825 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Page 7826 Cellular Phone Microphone: Description and Operation ONSTAR(R) MICROPHONE The OnStar(R), or cellular, microphone can be part of the rearview mirror assembly, or on some vehicle lines, can be a separate, stand alone unit. In either case, the microphone is supplied voltage on the cellular microphone signal circuit, while voice data from the user is sent back to the VCIM by means of either a cellular microphone low reference circuit or a drain wire. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Page 7827 Cellular Phone Microphone: Service and Repair The content of this article reflects the changes identified in TSB 05-08-46-007 Bulletin No.: 05-08-46-007 Date: October 05, 2005 SERVICE MANUAL UPDATE Subject: Addition of OnStar(R) Microphone Replacement Procedure Models: 2002-2004 Buick Regal 2002-2005 Buick Century, LeSabre, Park Avenue 2005 Buick Allure (Canada Only), LaCrosse 2002-2005 Chevrolet Impala, Monte Carlo 2005 Chevrolet Colorado 2005 GMC Canyon 2002-2005 Pontiac Bonneville, Grand Prix OnStar(R) Microphone Replacement Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Cellular Phone Microphone > Component Information > Technical Service Bulletins > Page 7828 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 7837 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 7838 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 7839 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 7845 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 7846 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 7847 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - DIC Perceived Fuel Economy Settings Driver/Vehicle Information Display: Technical Service Bulletins Instruments - DIC Perceived Fuel Economy Settings Bulletin No.: 03-00-89-021 Date: July 30, 2003 INFORMATION Subject: New Vehicle Pre-Delivery Inspection - Perceived Fuel Economy and Driver Information Center (DIC) Settings Models: 2003-2004 Passenger Cars and Trucks 2003-2004 HUMMER H2 with Driver Information Center (DIC) The customer's initial perception of vehicle fuel economy, based upon the information displayed on the Driver Information Center (DIC), may contribute to poor ratings for fuel economy in various automotive surveys. The way the vehicle is handled during the build and shipping process may leave inaccurate values in the history of the DIC. During the pre-delivery inspection, the dealership must reset the "average fuel economy" setting. Reset the average fuel economy setting according to the information in the appropriate Owner's Manual. Once reset, the average fuel economy will then be calculated starting from that point. The data used to determine fuel range is an average of recent driving conditions. This setting cannot be reset. However, as the customer's driving conditions change, the data will be gradually updated to reflect more accurate readings. If a customer inquires about fuel economy, and the fuel consumption information is not on the price sticker, do not exaggerate the vehicle's capabilities. In either case, stress that fuel economy performance is highly dependent upon driving habits and vehicle usage. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 7852 Driver/Vehicle Information Display: Diagrams Driver Information Center (DIC), C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 7853 Driver Information Center (DIC), C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 7854 Driver Information Center (DIC), C2 (With RPO Code CF5) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 7855 Driver/Vehicle Information Display: Description and Operation DRIVER INFORMATION CENTER (DIC) DESCRIPTION AND OPERATION When the driver information center (DIC) powers up it will display all segments on for 2 seconds. Then the DIC will return to display status it had before no power condition. In the absence of vehicle communications, a double dash (--) displays in the digits section. An error of the speed sensor or fuel sender will cause -E- to be displayed. There are 2 buttons on the DIC. - RESET button - MODE button RESET BUTTON You can reset the AVG ECON, FUEL USED or AVG SPEED trip computer modes by pressing and holding the RESET button for three seconds while you are in the mode you wish to reset. A chime will sound to confirm that your requested change has been made and all the segments of the display will briefly light up. To change the display to a metric or English reading, press the RESET and MODE buttons at the same time. Hold them down for three seconds, and the display will change. A chime will be heard to confirm the new selection. The DIC will send a class 2 message to the IPC to change the units displayed in the odometer. MODE Button The display format for each mode is indicated in the shown table. Pressing the MODE button changes the modes of operation for the DIC. There are seven display modes available. Off - No driver information is displayed in this mode of operation. - Compass/Temperature - Average Fuel Economy (AFE) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 7856 - Instantaneous Fuel Economy (IFE) - Trip Range - Fuel Used - Average Speed COMPASS/TEMPERATURE MODE This mode displays an 8 point compass heading on the left hand side of the DIC. The compass will display the current vehicle direction relative to one of 8 compass headings using N, NE, E, SE, S, SW, W, and NW for the readout. The ambient temperature displays on the right hand side of the DIC. If the ambient temperature is below 3°C (37°F), the temperature reading will toggle between displaying the outside temperature and the word ICE for two minutes. If the temperature is less than minus 40°F for more than 2 seconds, OC will display. If the temperature is above 140°F for more than 2 seconds, SC will be displayed. If OC or SC is displayed DTC's will be set. For compass calibration and compass magnetic variation adjustment refer to Electronic Compass Calibration. AVERAGE FUEL ECONOMY (AVG) AFE is calculated as the ratio between the following values: AFE=Distance/Fuel - Distance=The accumulated distance since the last AFE reset - Fuel=The accumulated fuel consumption since the last AFE reset You can reset the AFE mode by pressing the RESET button for more than 3 seconds while in this mode. The value of this mode is retained during ignition OFF. INSTANTANEOUS FUEL ECONOMY (INST) Instantaneous fuel economy is calculated as the ratio between the following values: IFE=Distance/Fuel - Distance=The accumulated distance since last update - Fuel=The accumulated fuel delivered since last update You cannot reset the IFE mode. The value of this mode is retained during ignition OFF. TRIP RANGE (RANGE) Trip Range is calculated between the following values: Trip Range=AFE x Fuel Remaining - Fuel Remaining=Fuel sender value of available fuel You cannot reset the Trip Range mode. The value of this mode is retained during ignition OFF. FUEL USED The DIC calculates and displays the total amount of fuel used since the last reset operation. You can reset the Fuel Used mode by pressing the RESET button for more than 3 seconds while in this mode. The value of this mode is retained during ignition OFF. AVERAGE SPEED (AVG SPEED) Average speed is calculated as the ratio between the following values: Average Speed=Distance/Ignition On - Distance=Accumulated distance since last reset - Ignition On=Accumulated ignition on time since last reset Ignition on time is measured from the time that the ignition is turned ON, to the time when the ignition is turned OFF. You can reset the Average Speed mode by pressing the RESET button for more than 3 seconds while in this mode. The value of this mode is retained during ignition OFF. DIMMING CONTROL Display dimming for the DIC follows the radio dimming characteristics. Upon activation of the parklamps, the display steps from maximum brightness to dim. While in the dim mode, further dimming is controlled by the PWM Dimming Signal of the IP dimming control. The display goes blank upon lowest dimming request of the dimming control. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures Driver/Vehicle Information Display: Procedures Driver Info Center Replacement (With RPO Code UG1, Except CF5) DRIVER INFORMATION CENTER REPLACEMENT (UG1, EXC CF5) REMOVAL PROCEDURE IMPORTANT: The driver information center is serviced as part of the complete roof console. 1. Remove the roof console screw. 2. Use a small, flat-bladed tool in order to release the 2 retainers. These retainers are located on each side of the assembly in front of the switches. Press the retainers outward to release the roof console. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 7859 3. Lower the roof console from the headliner. 4. Disconnect the electrical connectors from the roof console. 5. Remove the roof console backing plate. 6. Remove the roof console. INSTALLATION PROCEDURE IMPORTANT: When installing the roof console, apply foam tape to the wiring harness. Secure the wiring harness in the proper position to the headliner. 1. Apply foam tape to the wiring harness at the headliner. 2. Install the roof console backing plate. 3. Connect the electrical connectors to the roof console. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 7860 4. Position the roof console to the roof console backing plate in the headliner. 5. Install the roof console by pressing the console into place until the retainers are completely engaged. NOTE: Refer to Fastener Notice in Service Precautions. 6. Install the roof console screw. Tighten Tighten the screw to 2 N.m (18 lb in). Driver Information Center Replacement (With RPO Code CF5) DRIVER INFORMATION CENTER REPLACEMENT (CF5) REMOVAL PROCEDURE IMPORTANT: The driver information center is serviced as part of the complete roof console. 1. Remove the roof console screw. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 7861 2. Use a small, flat-bladed tool in order to release the 2 retainers. These retainers are located on each side of the assembly in front of the switches. Press the retainers outward to release the roof console. 3. Lower the roof console from the headliner. 4. Disconnect the electrical connectors from the roof console. 5. Remove the roof console. 6. Remove the sunshade anchors. 7. Lower the headliner at the sunroof opening. Reach between the headliner and the roof to remove the foam tape from the wiring harness on the roof console backing plate. 8. Adjust the wiring harness for access. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 7862 9. Slide the roof console backing plate (2) forward and remove the backing plate from the front of the headliner. INSTALLATION PROCEDURE 1. Position the roof console backing plate (2) to the headliner opening. 2. Secure the wiring harness in the original position to the roof console backing plate. 3. Connect the electrical connectors to the roof console. 4. Install the headliner. 5. Install the sunshade anchors. 6. Position the roof console to the roof console backing plate in the headliner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 7863 7. Install the roof console by pressing the console into place until the retainers are completely engaged. NOTE: Refer to Fastener Notice in Service Precautions. 8. Install the to the roof console screw. Tighten Tighten the screw to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 7864 Driver/Vehicle Information Display: Removal and Replacement Driver Information Center Replacement (CF5) Driver Information Center Replacement (CF5) Removal Procedure Important: The driver information center is serviced as part of the complete roof console. 1. Remove the roof console screw. 2. Use a small, flat-bladed tool in order to release the 2 retainers. These retainers are located on each side of the assembly in front of the switches. Press the retainers outward to release the roof console. 3. Lower the roof console from the headliner. 4. Disconnect the electrical connectors from the roof console. 5. Remove the roof console. 6. Remove the sunshade anchors. 7. Lower the headliner at the sunroof opening. Reach between the headliner and the roof to remove the foam tape from the wiring harness on the roof console backing plate. Refer to Headliner Replacement (Impala) Headliner Replacement (Monte Carlo) in Interior Trim. 8. Adjust the wiring harness for access. 9. Slide the roof console backing plate (2) forward and remove the backing plate from the front of the headliner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 7865 Installation Procedure 1. Position the roof console backing plate (2) to the headliner opening. 2. Secure the wiring harness in the original position to the roof console backing plate. 3. Connect the electrical connectors to the roof console. 4. Install the headliner. 5. Install the sunshade anchors. 6. Position the roof console to the roof console backing plate in the headliner. 7. Install the roof console by pressing the console into place until the retainers are completely engaged. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the to the roof console screw. Tighten the screw to 2 N.m (18 lb in). Driver Information Center Replacement (UG1, EXC CF5) Driver Information Center Replacement (UG1, EXC CF5) Removal Procedure Important: The driver information center is serviced as part of the complete roof console. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 7866 1. Remove the roof console screw. 2. Use a small, flat-bladed tool in order to release the 2 retainers. These retainers are located on each side of the assembly in front of the switches. Press the retainers outward to release the roof console. 3. Lower the roof console from the headliner. 4. Disconnect the electrical connectors from the roof console. 5. Remove the roof console backing plate. 6. Remove the roof console. Installation Procedure Important: When installing the roof console, apply foam tape to the wiring harness. Secure the wiring harness in the proper position to the headliner. 1. Apply foam tape to the wiring harness at the headliner. 2. Install the roof console backing plate. 3. Connect the electrical connectors to the roof console. 4. Position the roof console to the roof console backing plate in the headliner. 5. Install the roof console by pressing the console into place until the retainers are completely engaged. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the roof console screw. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 7867 Tighten the screw to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7876 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7877 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7878 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7879 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7880 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7881 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7882 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7883 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7884 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7885 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7886 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7887 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7888 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7889 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7890 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7891 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7892 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7893 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7894 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7895 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7896 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7897 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7898 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7899 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7900 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7901 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7902 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7903 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7904 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7905 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7906 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7907 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7908 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7909 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 7915 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: Customer Interest OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 7920 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 7925 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 7930 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 7931 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 7937 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7946 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7947 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7948 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7949 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7950 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7951 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7952 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7953 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7954 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7955 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7956 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7957 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7958 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7959 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7960 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7961 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7962 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7963 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7964 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7965 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7966 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7967 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7968 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7969 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7970 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 7971 Circuit/System Testing Component Testing Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7976 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7977 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7978 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7979 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7980 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7981 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7982 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7983 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7984 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7985 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7986 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7987 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7988 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7989 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7990 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7991 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7992 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7993 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7994 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7995 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7996 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7997 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7998 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 7999 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8000 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8001 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8002 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8003 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8004 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8005 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8006 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8007 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8008 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8009 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8014 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8015 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8016 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8017 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8018 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8019 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8020 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8021 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8022 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8023 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8024 Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8025 Labor Time Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 8030 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 8039 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 8048 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 8053 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 8054 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 8060 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8069 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8070 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8071 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8072 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8073 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8074 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8075 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8076 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8077 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8078 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8079 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8080 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8081 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8082 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8083 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8084 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8085 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8086 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8087 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8088 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8089 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8090 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8091 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8092 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8093 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8094 Circuit/System Testing Component Testing Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8099 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8100 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8101 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8102 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8103 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8104 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8105 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8106 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8107 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8108 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8109 Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8110 Labor Time Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 8115 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 8124 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 8133 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 8138 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 8139 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8149 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8150 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8151 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8152 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8153 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8154 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8155 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8156 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8157 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8158 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8159 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8160 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8161 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8162 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8163 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8164 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8165 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8166 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8167 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8168 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8169 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8170 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8171 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8172 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8173 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8174 Circuit/System Testing Component Testing Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8179 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8180 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8181 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8182 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8183 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8184 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8185 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8186 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8187 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8188 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8189 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8190 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8191 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8192 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8193 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8194 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8195 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8196 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8197 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8198 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8199 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8200 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8201 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8202 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8203 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8204 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8205 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8206 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8207 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8208 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8209 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8210 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8211 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8212 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8217 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8218 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8219 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8220 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8221 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8222 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8223 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8224 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8225 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8226 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8227 Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8228 Labor Time Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 8233 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Entertainment Systems > Headphones / Earphones > Component Information > Technical Service Bulletins > Entertainment System - Headphone Foam Pad Replacement Headphones / Earphones: Technical Service Bulletins Entertainment System - Headphone Foam Pad Replacement Bulletin No.: 05-08-44-005A Date: July 19, 2007 INFORMATION Subject: Information on Rear Seat Headphone Foam Ear Pad Replacement if Worn or Damaged Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2, H3 2005-2008 Saab 9-7X with Rear Seat Entertainment System (RPOs U32, U42) Supercede: This bulletin is being revised to add models and model years and update the shipping costs. Please discard Corporate Bulletin Number 05-08-44-005 (Section 08 - Body and Accessories). Foam ear pads on the rear headphone may become worn or damaged. The headphone foam ear pads may wear out when not handled and stored carefully. If the headphone foam ear pads become damaged or worn out, the foam pads can be replaced separately from the headphone set. It is not necessary to replace the complete headphone set. Parts Information All pricing information listed in this bulletin is in U.S. dollars and is subject to change without notice. The headphone replacement foam ear pads can be ordered in pairs directly through the supplier. Have your customer call Unwired at 1-888-293-3332, then prompt zero (0). The replacement, P/N CS-980 (thick earfoam), can be ordered for $3.50 (USD) per pair plus $2.50 USPS shipping. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Locations Driver Information Center (DIC) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions Garage Door Opener Transmitter: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8252 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8253 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8254 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8255 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8256 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8257 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8258 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8259 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8260 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8261 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8262 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8263 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8264 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8265 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8266 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8267 Garage Door Opener Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8268 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8269 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8270 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8271 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8272 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8273 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8274 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8275 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8276 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8277 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8278 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8279 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8280 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8281 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8282 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8283 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8284 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8285 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8286 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8287 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8288 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8289 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8290 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8291 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8292 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8293 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8294 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 8295 Garage Door Opener Transmitter: Electrical Diagrams Garage Door Opener Diagram Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Diagrams > Page 8296 Garage Door Opener Transmitter: Description and Operation GARAGE DOOR OPENER DESCRIPTION AND OPERATION The garage door opener is located in the overhead console. The valet switch provides battery voltage to the garage door opener. If battery voltage is lost due to a condition such as a dead battery, the garage door opener unit relies on the non-servicable internal power backup supply. The unit is programmed using the customer's hand-held transmitters for the garage doors, electric entrance gates, or lighting and security systems. The garage door opener is rolling code capable. Rolling code is a system that allows the code that the customers receiver receives from the garage door opener to change every time the garage door opener is used within operating range of the receiver. When the receiver and the garage door opener are initially programmed together, a code is established, a new code is created for every new transmission. The software in the receiver recognizes the garage door opener and accepts the new code. The garage door opener is compatible with most, but not all types and brands of transmitters. If a problem should occur with a compatibility conflict with a transmitter, call HomeLink(TM) at 1-800-355-3515. The garage door opener is a transmitter operating between 288-399 MHz. The power and range of the transmitter is limited to comply with laws governing the generation of radio frequency interference (RFI). The transmitter is programmed by the user to accept the signal generated by the user's transmitters, refer to Garage Door Opener Programming - Universal. The garage door opener has 3 buttons that may be programmed for individual transmitter/receiver combinations to control up to 3 garage door openers, security gates, and lighting systems. Each button represents a transmitter code section of the transmitter, which operates separately from any other button, and may be considered a separate transmitter. Operation consists of simply pressing a button to activate the corresponding transmitter. Battery voltage is provided to the garage door opener from the IGN SEN fuse in the IP fuse block. The garage door opener is grounded through G400. Inadvertent power is supplied from the body control module (BCM). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Garage Door Opener Transmitter: Initial Inspection and Diagnostic Overview DIAGNOSTIC STARTING POINT - GARAGE DOOR OPENER Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure to use when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Garage Door Opener in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8299 Garage Door Opener Transmitter: Symptom Related Diagnostic Procedures - Symptoms - Garage Door Opener SYMPTOMS - GARAGE DOOR OPENER IMPORTANT: Review the system description and operation in order to familiarize yourself with the system functions. Refer to Garage Door Opener Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which could affect the operation of the garage door opener. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to Garage Door Opener Inoperative in order to diagnose the symptom. Steps 1-2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8300 Steps 3-11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement Garage Door Opener Transmitter: Service and Repair Garage Door Opener Replacement GARAGE DOOR OPENER REPLACEMENT The universal garage door opener (UGD0) is serviced as part of the overhead console. Refer to Console Replacement - Overhead in Interior Trim. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement > Page 8303 Garage Door Opener Transmitter: Service and Repair Garage Door Opener Programming Universal GARAGE DOOR OPENER PROGRAMMING - UNIVERSAL GARAGE DOOR OPENER PROGRAMMING IMPORTANT: Do not use the garage door opener (GDO) with any garage door opener that does not have the stop and reverse safety feature. This includes any garage door opener model manufactured before April 1, 1982. Be sure that people and objects are clear of the garage door you are programming. The GDO is programmed by using the customer's hand-held transmitter(s). Turn the ignition OFF while programming the GDO transmitter. Follow these steps to program up to 3 channels: 1. If you have previously programmed a transmitter, proceed to Step 2. Otherwise, hold down the 2 outside buttons on the GDO transmitter for approximately 20 seconds, until the light on the GDO transmitter begins to flash rapidly. Then release the buttons. This procedure erases any previous settings and initializes the memory for all 3 channels. 2. Decide which of the 3 channels you want to program to the transmitter you have. 3. Hold the end of the hand-held transmitter against the front surface of the GDO (less than 1 inch) so you can still see the light. 4. Using both hands, press the hand-held transmitter button and the desired button on the GDO transmitter. Continue to hold both buttons through Step 5. IMPORTANT: The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink(TM) at 1-800-355-3515 in order to address this problem. 5. Hold down the buttons on both transmitters until you see the light on the GDO transmitter flash slowly and then rapidly. The rapid flashing, which could take up to 90 seconds, indicates that the GDO transmitter has been programmed. Release the buttons on both transmitters when the light starts to flash rapidly. TRAINING THE GDO FOR ROLLING CODE RECEIVERS This procedure is for training the customer's rolling code garage door openers to their GDO transmitter. The GDO must already be programmed to its hand-held transmitter. The training process below must be completed within 30 seconds or it must be repeated. 1. Locate the train button on the garage door opener receiver. Refer to the operator's manual for the garage door opener (or call HomeLink(TM) at 1-800-355-3515 for assistance). Follow instructions for the garage door opener in order to determine when the unit is in train mode. 2. Return to the GDO transmitter in the vehicle, and press the button that you want trained for rolling codes 3 times, for 1 second each time. If not successfully programmed, try 2-5 seconds each time. 3. Press the button used again in order to verify that the GDO transmitter has been programmed. You may use either the hand-held transmitter or the GDO to open the garage door. The GDO is compatible with most, but not all, types and brands of transmitters. If the GDO light does not flash rapidly after 90 seconds, there may be a compatibility conflict with the transmitter used to program the GDO. Call HomeLink(TM) at 1-800-355-3515 in order to address compatibility concerns. ERASING CHANNELS To erase programmed channels, hold down the 2 outside buttons until the light on the GDO transmitter begins to flash. Individual channels cannot be erased, but can be reprogrammed using the Garage Door Opener Programming and the Training GDO for Rolling Code Receivers procedures. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Garage Door Opener Replacement > Page 8304 NON-COMPATIBLE GARAGE DOOR OPENERS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Garage Door Opener Transmitter > Component Information > Service and Repair > Page 8305 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts Global Positioning System Antenna: Technical Service Bulletins OnStar(R) - Cellular Antenna Replacement Parts Bulletin No.: 00-08-46-002A Date: April 12, 2005 INFORMATION Subject: OnStar(R) System Cellular Antenna Replacement Parts Availability Models: 1996-2005 Passenger Cars and Light Duty Trucks 2003-2005 HUMMER H2 with OnStar(R) and Glass Mounted Antennas Supercede: This bulletin is being revised to update the model years, models and parts information. Please discard Corporate Bulletin Number 00-08-46-002 (Section 08 - Body & Accessories). Replacement parts for the OnStar(R) system cellular antenna are available as follows: ^ Cellular Antenna Kit - If the antenna mast or exterior base is damaged or missing or if the antenna base has separated from the exterior glass surface. ^ Cellular Antenna Inner Coupling - If the antenna coupling on the inside of the glass requires replacement. Important: If glass replacement is required, both the Cellular Antenna Kit and the Cellular Antenna Inner Coupling are required. The kits listed contain all the necessary parts and instructions needed to properly install a new cellular antenna exterior base or interior coupling to the glass surface. To obtain maximum adhesion during installation, the instructions included in the kits must be followed carefully and exactly as written. Important: Do not attempt to reinstall the original cellular antenna exterior base or interior coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system that includes air bag deployment notification. Important: To obtain maximum adhesion between the new cellular exterior base or interior coupling and the glass surface, the base, coupling and glass must be kept dry and above 15°C (60°F) during the installation and for the 24 hours immediately following the installation. Not keeping the vehicle dry and above the temperature listed for 24 hours may result in the new cellular antenna exterior base or interior coupling coming off. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Technical Service Bulletins > OnStar(R) - Cellular Antenna Replacement Parts > Page 8311 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner Global Positioning System Antenna: Service and Repair Coupling Replacement - Antenna Inner COUPLING REPLACEMENT - ANTENNA INNER REMOVAL PROCEDURE IMPORTANT: Use adhesion promoter to ensure adequate bonding of the coupling. - To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60°F) during installation. Allow 6 to 8 hours, at 15°C (60°F), for the adhesive to cure after installation. Otherwise, the new couplings may not adhere. - Do not attempt to reinstall the original cellular antenna exterior coupling or inner coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Disconnect the coaxial cable from the mobile communication antenna inner coupling. NOTE: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. 2. Use a small wide-bladed plastic tool to cut the double back tape material while lifting up on the inner antenna coupling (2). INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 8314 1. Clean the inside of the back glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. 3. Apply Glass Adhesion Promoter GM P/N 12378555 (Canadian P/N 88901239), to the back glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. IMPORTANT: The IF connections for the inner antenna coupling should run parallel to the defogger gridline. - Align the inner and outer antenna couplings. - Do not touch the adhesive backing on the antenna coupling. 1. If the exterior coupling is not installed, mark the inner antenna coupling location (A) 92 mm (3.75 in) and (B) 80 mm (3.25 in) with a grease pencil on the exterior surface of the rear window. 2. Remove the protective film from the adhesive backing on the inner antenna coupling. 3. Align the inner antenna coupling to the locating marks on the back glass or the exterior coupling. 4. Press firmly on all 4 corners and on the center of the antenna inner coupling (2) in order to ensure proper adhesion to the back glass (4). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 8315 Hold pressure on the inner coupling (2) for 10-30 seconds. 5. Ensure there are not any gaps between the couplings (5, 2) and the back glass (4). 6. Connect the coaxial cable to the inner coupling. 7. Keep the vehicle dry. Allow 6-8 hours, at 15°C (60°F), for the adhesive to cure after installation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 8316 Global Positioning System Antenna: Service and Repair Coupling Replacement - Antenna Outer COUPLING REPLACEMENT - ANTENNA OUTER REMOVAL PROCEDURE IMPORTANT: Use adhesion promoter to ensure adequate bonding of the coupling. - To obtain maximum adhesion between the new mobile antenna couplings and the glass surface, the couplings and the glass must be kept dry and above 15°C (60°F) during installation. Allow 6 to 8 hours, at 15°C (60°F), for the adhesive to cure after installation. Otherwise, the new couplings may not adhere. - Do not attempt to reinstall the original cellular antenna exterior coupling or inner coupling using any type of glue, adhesive tapes, etc. Doing so may eliminate the cellular signal transfer through the glass and reduce the maximum performance of the system, including the air bag deployment notification. 1. Install the inner coupling first if both the inner and the outer coupling are to be replaced. NOTE: If you use a razor blade or other sharp tool in order to remove the adhesives or foreign objects from the inside of the rear window, use the blade carefully. Damage to the grid lines may result. 2. Use a small wide-bladed plastic tool to cut the double back tape material while lifting up on the outer antenna coupling (5). INSTALLATION PROCEDURE 1. Clean back glass with an alcohol wipe. 2. Dry the glass thoroughly using a lint free cloth. 3. Apply Glass Adhesion Promoter GM P/N 12378555 (Canadian P/N 88901239) to the back glass in the area where you will install the antenna coupling. Follow the Glass Adhesion Promoter instructions on the product label. IMPORTANT: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 8317 - Align the inner and outer antenna couplings. - Do not touch the adhesive backing on the antenna coupling. 1. Remove the protective film from the adhesive backing on the outer antenna coupling. 2. Align the outer antenna coupling to the inner antenna coupling. 3. Press firmly on all 4 corners and on the center of the antenna outer coupling (5) in order to ensure proper adhesion to the back glass (4). Hold pressure on the outer coupling (5) for 10-30 seconds. 4. Ensure that no gaps occur between the couplings (5, 2) and the back glass (4). 5. Keep the vehicle dry. Allow 6-8 hours, at 15°C (60°F), for the adhesive to cure after installation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Antenna > Component Information > Service and Repair > Coupling Replacement - Antenna Inner > Page 8318 Global Positioning System Antenna: Service and Repair Navigation Antenna Replacement NAVIGATION ANTENNA REPLACEMENT REMOVAL PROCEDURE 1. Remove the rear shelf trim panel. 2. Adjust the acoustical barrier for access. 3. Remove the antenna assembly tape from the rear shelf. 4. Remove the global positioning system (GPS) antenna from the rear shelf using a small wide-bladed plastic tool in order to release the adhesive. 5. Disconnect the GPS antenna cable connector. 6. Clean the adhesive residue from the rear shelf using a razor blade and isopropyl alcohol pad and a clean lint-free cloth. INSTALLATION PROCEDURE 1. Clean the surface of the rear shelf in the (GPS) antenna mounting location, using an isopropyl alcohol pad and a clean lint-free cloth. 2. Connect the GPS antenna cable connector. IMPORTANT: Do not touch the adhesive backing. 3. Remove the protective backing from the adhesive on the GPS antenna. 4. Install the GPS antenna to the rear shelf surface. Press the GPS antenna into place until fully seated for approximately 30 seconds. 5. Secure the antenna assembly to the rear shelf with tape. 6. Install the acoustical barrier. 7. Install the rear shelf trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Service and Repair Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification and the 11-digit electronic serial number, are used by the National Cellular Network and OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 1. Open the rear compartment. 2. Remove the communication interface module cover. 3. Remove the bracket nuts from the communication interface module. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Service and Repair > Page 8322 4. Adjust the assembly for access. 5. Disconnect the cellular antenna cable from the communication interface module. 6. Disconnect the electrical connectors from the module. 7. Disconnect the GPS antenna cable from the module. 8. Remove the bolts (1) from the communication interface module. 9. Remove the communication interface module (2). INSTALLATION PROCEDURE 1. Record the 11-digit electronic serial number (ESN) and the 10-digit station identification (STID) number from the label on the new VCIM. 2. Position the communication interface module to the bracket (2). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the communication interface module bolts (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Service and Repair > Page 8323 Tighten Tighten the bolts to 10 N.m (89 lb in). 4. Connect the GPS antenna cable to the module. 5. Connect the electrical connectors to the module. 6. Connect the cellular antenna cable to the module. IMPORTANT: After replacing the communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. 7. Reconfigure the OnStar(R) system. Refer to OnStar Reconfiguration. 8. Position the assembly to the studs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Global Positioning System > Global Positioning System Module > Component Information > Service and Repair > Page 8324 9. Install the bracket nuts to the communication interface module. Tighten Tighten the nuts to 4 N.m (35 lb in). 10. Install the communication interface module cover. 11. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Description and Operation > Personalization Memory Positioning Systems: Description and Operation Personalization PERSONALIZATION DESCRIPTION AND OPERATION Personalization features may be set for the vehicle or the driver. Vehicle features do not change with each driver. Specific drivers are recognized by the vehicle through the keyless entry transmitters, the memory buttons, or the driver information center (DISC), and the personalization settings for that driver are recalled. For more information on vehicle personalization features for this vehicle, refer to Vehicle Personalization. This vehicle does not have specific driver personalization available. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 8329 Memory Positioning Systems: Description and Operation Driver Personalization DRIVER PERSONALIZATION PERSONAL CHOICE RADIO CONTROLS With this feature the vehicle will recall the latest radio settings as adjusted the last time the vehicle was operated. Perform the following steps in order to Personalize the Personal Choice Radio Controls feature: 1. Press the Unlock button on key fob 1. 2. Turn the ignition to Run. 3. Select and Set all of the following settings: - AM/FM presets - Last tuned station - Volume - Tone - Audio source; Radio, Cassette or CD 4. Turn ignition Off. Repeat this procedure using key fob 2 to program the desired settings for driver 2. ADDITIONAL INFORMATION Refer to Radio/Audio System Description and Operation in Radio, Stereo and Compact Disc for more information about the Personal Choice Radio Controls feature. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 8330 Memory Positioning Systems: Description and Operation Vehicle Personalization VEHICLE PERSONALIZATION PROGRAMMING FEATURES ENTER PROGRAMMING MODE Perform the following steps in order to enter the programming mode: 1. Press the DISP button on radio for at least 10 seconds. 2. Press the SEEK button to scroll through the menu. DELAYED HEADLAMP ILLUMINATION Continue with the following steps in order to personalize the delayed headlamp illumination feature: 1. Scroll through the menu, using the SEEK button, until LT. DELAY is displayed. 2. Press the DISP button to enter the menu. 3. Press the PREV or NEXT button to scroll through the following options: - DISABLED - 30 SEC - 60 SEC - RETURN 4. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. AUTOMATIC DOOR LOCKS Continue with the following steps in order to personalize the automatic door locks feature: 1. Scroll through the menu, using the SEEK button, until AUTOLOCK is displayed. 2. Press the DISP button to enter the menu. 3. Press the PREV or NEXT button to scroll through the following options: - OFF - LCK ONLY - DRVR UNL - ALL UNL 4. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. REMOTE ACTIVATION VERIFICATION Continue with the following steps in order to personalize the remote activation verification feature: 1. Scroll through the menu, using the SEEK button, until FOBLIGHT is displayed. 2. Press the DISP button to enter the menu. 3. Press the PREV or NEXT button to scroll through the following options: - OFF - ON 4. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. 5. Exit to the MAIN MENU. 6. Scroll through the menu, using the SEEK button, until FOBHORN is displayed. 7. Press the DISP button to enter the menu. 8. Press the PREV or NEXT button to scroll through the following options: - OFF - PARTIAL - FULL 9. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. CONTENT THEFT DETERRENT Continue with the following steps in order to personalize the content theft deterrent options: 1. Scroll through the menu, using the SEEK button, until ALARM is displayed. 2. Press the DISP button to enter the menu. 3. Press the PREV or NEXT button to scroll through the following options: - OFF - ON 4. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. 5. Exit to the MAIN MENU. 6. Scroll through the menu, using the SEEK button, until TRNKJAMB is displayed. 7. Press the DISP button to enter the menu. 8. Press the PREV or NEXT button to scroll through the following options: - OFF - ON 9. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 8331 HORN CHIRP TIMER Continue with the following steps in order to personalize the duration of the horn chirp when the remote keyless transmitter is used: 1. Scroll through the menu, using the SEEK button, until CHIRP is displayed. 2. Press the DISP button to enter the menu. 3. Press the PREV or NEXT button to scroll through the following options: - SHORT - Short Chirp (16 msec) - LONG - Long Chirp (32 msec) 4. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. EXIT PROGRAMMING Continue with the following steps in order to exit the programming mode: 1. Press the SEEK button to scroll to the end of the MAIN MENU until EXIT is displayed. 2. Press the DISP button to exit the MAIN MENU. PROGRAMMING FEATURES WITH THE TECH 2 To enter programming with the Tech 2, perform the following actions: 1. Install the scan tool. 2. Turn ON the ignition with the engine OFF. 3. Select the correct vehicle and model year. 4. Select Body. 5. Select Personalization. DELAYED HEADLAMP ILLUMINATION Continue with the following steps in order to program the Delayed Headlamp Illumination feature: 1. Select Set Options. 2. Select F0 for Delayed Headlamp Illumination mode. 3. Highlight the desired mode from the following choices: - Mode 1: OFF - Mode 2: 30 seconds - Mode 3: 60 seconds 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. AUTOMATIC DOOR LOCK Continue with the following steps in order to program the Automatic Door Lock feature: 1. Select Set Options. 2. Select F1 for Automatic Door Lock Mode. 3. Highlight the desired mode for the following choices: - OFF - ADL out of Park - Unlock Drivers Door Only - Unlock All Doors 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. REMOTE VISUAL VERIFICATION MODE Continue with the following steps in order to program the Remote Unlock Verification Mode: 1. Select Set Options. 2. Select F2 for Remote Visual Verification Mode. 3. Highlight the desired mode for the following choices: - OFF - ON 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. REMOTE AUDIBLE VERIFICATION MODE Continue with the following steps in order to program the Remote Audible Verification Mode: 1. Select Set Options. 2. Select F3 for Remote Audible Verification Mode. 3. Highlight the desired mode for the following choices: - OFF - PARTIAL Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 8332 - FULL - DRL and Horn 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. CONTENT THEFT DETERRENT Continue with the following steps in order to program the CTD (Content Theft Deterrent System): 1. Select Set Options. 2. Select F4 for CTD Program Mode. 3. Highlight the desired mode for the following choices: - OFF - ON 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. CTD SHOCK SENSOR Continue with the following steps in order to program the CTD Shock Sensor. 1. Select Set Options. 2. Select F5 for CTD Program Mode. 3. Highlight the desired mode for the following choices: - OFF - ON 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. CTD TRUNK SWITCH Continue with the following steps in order to program the CTD Trunk Switch. 1. Select Set Options. 2. Select F6 for CTD Program Mode. 3. Highlight the desired mode for the following choices: - OFF - ON 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. HORN CHIRP MODE Continue with the following steps in order to program the Horn Chirp Mode. 1. Select Set Options. 2. Select F7 for Horn Chirp Mode. 3. Highlight the desired mode for the following choices: - Short Chirp - Long Chirp 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. POLICE OPTION (RPO A98) Continue with the following steps in order to program the Police Option Mode: 1. Select Set Options. 2. Select F8 Police Option Mode. 3. Highlight the desired mode for the following choices: - NO - YES 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. TRAP ALERT SYSTEM Continue with the following steps in order to program the Trap Alert System: 1. Select Set Options. 2. Select F9 Trap Alert System. 3. Highlight the desired mode for the following choice: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 8333 4. ENABLE 5. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 6. Select Save Options. 7. Exit the menu. ADDITIONAL INFORMATION For more information about the personalization features, refer to one of the following description and operations: Refer to Content Theft Deterrent (CTD) Description and Operation in Theft Deterrent for more information about the content theft deterrent features. - Refer to Power Door Locks Description and Operation in Doors for more information about the automatic door lock feature. - Refer to Interior Lighting Systems Description and Operation in Lighting Systems for more information about the delayed headlamp illumination feature. - Refer to Keyless Entry System Description and Operation in Keyless Entry for more information about remote activation verification. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 8342 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 8343 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 8344 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8349 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8350 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8351 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8352 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8353 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8354 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8355 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8356 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8357 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8358 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8359 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8360 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8361 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8362 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8363 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8364 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8365 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8366 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8367 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8368 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8369 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8370 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8371 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8372 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8373 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8374 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8375 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8376 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8377 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8378 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8379 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8380 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8381 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8382 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 8388 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 8393 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 8399 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation - Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 8408 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 8413 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 8414 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 8415 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8424 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8425 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8426 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8427 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8428 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8429 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8430 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8431 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8432 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8433 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8434 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8435 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8436 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8437 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8438 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8439 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8440 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8441 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8442 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8443 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8444 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8445 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8446 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8447 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8448 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 8449 Circuit/System Testing Component Testing Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8454 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8455 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8456 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8457 Diagnostic Tips Review Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8458 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8459 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8460 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8461 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8462 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8463 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8464 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8465 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8466 Diagnostic Tips Review # 3 - Denso Navigation Radios Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8467 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8468 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8469 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8470 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8471 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8476 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8477 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8478 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8479 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8480 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8481 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8482 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8483 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8484 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8485 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8486 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8487 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8488 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8489 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8490 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8491 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8492 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8493 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8494 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8495 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8496 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8497 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8498 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8499 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8500 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8501 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8502 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8503 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8504 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8505 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8506 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8507 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8508 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8509 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8514 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8515 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8516 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8517 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8518 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8519 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8520 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8521 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8522 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8523 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8524 Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 8525 Labor Time Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Navigation System: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 8530 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 08-08-44-023 > Jun > 08 > Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 8547 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Navigation System: > 07-08-44-007 > Apr > 07 > Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) Number Incorrect/Incorrectly Assigned Navigation System: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-004C > Dec > 10 > OnStar(R) Number Incorrect/Incorrectly Assigned > Page 8557 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10-08-44-006 > Oct > 10 > Navigation Report Missing/Inaccurate Nav. Map Info Navigation System: All Technical Service Bulletins Navigation - Report Missing/Inaccurate Nav. Map Info INFORMATION Bulletin No.: 10-08-44-006 Date: October 11, 2010 Subject: Reporting Missing or Inaccurate Navigation Radio Map Disc Information - Complete and Submit Feedback Form at GM Navigation Disc Center Website Models: 2011 and Prior GM Passenger Cars and Trucks Equipped with Navigation Radio Some customers may notice that some navigation radio map discs may have missing or incorrect information. The following list contains some examples: - Missing or incorrect roads, road names or road shapes - Missing or incorrect addresses - Missing or incorrect highway labeling - Missing or incorrect highway exit numbers - Missing or incorrect traffic restrictions - Missing points of interest (POI) or incorrect details, such as location, category or phone number General Motors uses a map database from two different suppliers. The two map suppliers are consistently updating their map database and will gladly accept any input regarding missing or incorrect information on the navigation radio map disc. To report any missing or incorrect information, please access the GM Navigation Disc Center at the following web site: http://www.gmnavdisc.com. At the GM Navigation Disc Center home page, select the tab: Your Feedback. In the Navigation Data Feedback form, fill in the appropriate information as required and then select: Submit, to send the form. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program Navigation System: All Technical Service Bulletins Navigation System - Software/DVD Update Program INFORMATION Bulletin No.: 06-08-44-012E Date: April 20, 2010 Subject: DVD Navigation Update Program, Navigation Disc Diagnostic Aid, AVN Software Update Discs and Ordering Information Models: 2002-2010 GM Passenger Cars and Trucks (including Saturn) 2004-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: Please direct this information to your Sales Consultants, Service Consultants, Parts Personnel and Used Car Department. This bulletin ONLY applies to North American dealers/retailers. Supercede: This bulletin is being revised to include the 2010 model year and update the usage table. Please discard Corporate Bulletin Number 06-08-44-012D (Section 08 - Body and Accessories). DVD Navigation Update Program The data on the DVD map disc ages at a rate of 15-20% per year. As the data ages, the functionality of the navigation system declines. Offering GM customers new navigation DVDs will ensure that the customers have the latest information for their system. General Motors offered a Navigation Disc Update Program for 2006 and 2007 model year vehicles. This program concluded on December 31, 2009. The DVD Navigation Update Program policy has changed and customers are no longer eligible for free annual updates, however, a navigation DVD update disc can be purchased for $199 (USD) + shipping. If the navigation disc is needed for a warranty situation, the disc can be purchased for $120 (USD). The dealer must provide a VIN and RO# to qualify for the reduced price. The dealer must call the GM Navigation Disc Center, as this option is not available on the website. The GM Navigation Disc Center launched on March 15, 2006. There are two ways to obtain an updated disc: - Via the web through gmnavdisc.com - GM Navigation Disc Center Navigation Disc Diagnostic Aid The following table can be used to identify acceptable discs for testing the navigation unit's map drive functionality. This should only be used to verify the map drive's ability to read the map disc properly and to determine if there is an issue with the unit's map drive or the disc. Some functions, such as voice recognition, may not work properly with some of the discs in the list. If the disc is found to be defective always contact the GM Navigation Disc Center to obtain the most recent disc for the vehicle. AVN Software Update Discs Technical Service Bulletins are sometimes generated to address specific navigation radio operational or performance issues. When a navigation radio bulletin is issued, it may contain instructions to utilize an advanced vehicle navigation (AVN) software update with a specific part number. GM dealers must order advanced vehicle navigation (AVN) software update discs as directed in the specific bulletin. AVN software update discs are for the dealer to update the navigation radio software only. They do NOT update or replace the navigation map disc that is supplied with the vehicle. Please order these parts only as needed. There is a limited supply of these discs available. Do not order these discs for stock. AVN software update discs can be used to reprogram more than one vehicle. The first update disc for each P/N is free. Subsequent copies of the same P/N for the same dealer will cost $50 (USD). To obtain an AVN software update disc, follow the specific ordering information provided in the bulletin. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 8566 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-44-007D > May > 09 > OnStar(R) Negative Impact of Cloth/Vinyl Roofs Navigation System: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8575 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8576 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8577 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8578 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8579 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8580 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8581 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8582 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8583 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8584 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8585 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8586 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8587 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8588 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8589 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8590 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8591 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8592 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8593 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8594 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8595 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8596 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8597 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8598 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8599 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8600 Circuit/System Testing Component Testing Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips Navigation System: All Technical Service Bulletins Navigation Radio - Diagnostic Tips INFORMATION Bulletin No.: 08-08-44-010F Date: March 09, 2009 Subject: Navigation Radio Diagnostic Tips Models: 2008 and Prior GM Passenger Cars and Trucks (Including Saturn) 2008 and Prior HUMMER H2, H3 2008 and Prior Saab 9-7X All Equipped with Navigation Radio Supercede: This bulletin is being revised to update the model years involved, the radio part number list, remove the PQC parts restriction and revise the diagnostic information. Please discard Corporate Bulletin Number 08-08-44-010E (Section 08 - Body and Accessories). Recent part reviews indicate that the majority of Navigation Radios returned for analysis do not test as defective. In many cases, published SI documents were available to correct the condition without the need for an exchange unit. The following Diagnostic Tips may assist with the proper diagnosis and repair of Navigation Radio Concerns. Note For U.S. dealers the 2009 and 2010 Model Year Navigation Radios are currently on restriction through the Technical Assistance Center (TAC). Refer to PI PIC5102. To order Radios and Instrument Panel Clusters (IPC) for 2008 and prior model year vehicles, please continue to follow the normal process and contact an authorized Electronic Service Center (ESC) for assistance. For any Navigation Radio replaced, a copy of the Repair Order (RO) must be included with the returned radio. Be sure to document the customer's concern in detail, including unusual noises and what functions are affected. List any Diagnostic Trouble Codes (DTCs) on the RO. Ensure the radio is sufficiently protected during shipping to prevent damage to the radio assembly. Note Navigation Radios with physical damage (for example: shattered displays, impact damage to the radio face and fluid damage) must be reviewed with the District Service Manager for appropriate coverage prior to replacing the radio. The dealership must note the District Service Manager's approval on the Repair Order, along with the reason for the goodwill assistance. Do NOT disassemble the radio to try and retrieve stuck CDs/DVDs as this may result in a debit to the dealership. Refer to Corporate Bulletin Number 08-08-44-015, Information on Inappropriate Warranty Claims submitted for Damaged Radios and Instrument Panel Clusters. Getting Started Retrieve the Navigation Radio part number using the Tech 2(R). Refer to Corporate Bulletin Number 04-08-44-005C - Utilizing Tech 2 to Retrieve Part Numbers for Radios, Compact Disc (CD) Changers and Instrument Panel Clusters (IPC). Use the table below to determine the appropriate Diagnostic Tips Review to follow based on the radio part number. Scroll down the bulletin to find the corresponding Diagnostic Tips Review. Printing This Document To print the applicable Diagnostic Tips Review pages, select File then Print Preview. Use the arrows at the top of the screen to scroll left and right through the bulletin to identify the correct pages containing the questions. With the pages identified, click on the Print button at the top left. In the pop-up box, select "Pages" in the "Print Range" and type in the pages. For example, to print pages 19 through 22, type in the box provided "19-22". Once the page range has been filled in, click the Print box at the bottom of the pop-up box. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8605 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8606 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8607 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8608 Diagnostic Tips Review Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8609 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8610 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8611 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8612 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8613 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8614 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8615 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8616 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8617 Diagnostic Tips Review # 3 - Denso Navigation Radios Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8618 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8619 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8620 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8621 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8622 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8627 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8628 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8629 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8630 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8631 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8632 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8633 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8634 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8635 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8636 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8637 Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8638 Labor Time Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) Analog/Digital System Information Navigation System: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) Analog/Digital System Information > Page 8643 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-46-004 > Aug > 08 > OnStar(R) Aftermarket Device Interference Information Navigation System: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-023 > Jun > 08 > Navigation Radio - Adaptation After Radio/Battery R&R; Navigation System: All Technical Service Bulletins Navigation Radio - Adaptation After Radio/Battery R&R; INFORMATION Bulletin No.: 08-08-44-023 Date: June 18, 2008 Subject: Information On Navigation Radio Not Displaying Accurate Vehicle Location After Radio Replacement, Power Loss Or Battery Replacement Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X with Navigation Radio The purpose of this bulletin is to inform technicians and customers that the Navigation Radio may not display the vehicle location icon on the map accurately after a radio or battery has been replaced or after battery power has been removed from the radio. The vehicle location icon accuracy may be degraded if the GPS signal is not available and the GPS displayed icon has a red line through it. The Navigation Radio does not keep learned GPS information or gyroscope and vehicle speed signals stored when the battery power is removed from the radio. The Navigation radio continually uses GPS, gyroscope and vehicle speed data to maintain the vehicle location icon positioned accurately on the displayed map. There may be periods of time during a drive cycle when the GPS signal may not be available and the vehicle location icon still appears to be accurate. This is due to the radio having internal gyroscopes and receiving a vehicle speed signal to maintain accuracy if the radio had received a good GPS signal earlier in the drive cycle. Normal driving will improve the accuracy of the vehicle location icon on the displayed map. It may be necessary for the vehicle to be driven up to 40 km (25 mi) with 15 left and 15 right turns while the vehicle location icon is matched to roads on the displayed map. Do not replace the radio for this condition. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 00-08-46-004C > Jan > 08 > OnStar(R) Re-establishing OnStar(R) Communications Navigation System: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) Incorrect GPS Position Reported During Call Navigation System: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 02-08-46-006C > Jan > 08 > OnStar(R) Incorrect GPS Position Reported During Call > Page 8660 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 07-08-44-007 > Apr > 07 > Navigation System - Replacement Navigation Discs Navigation System: All Technical Service Bulletins Navigation System - Replacement Navigation Discs Bulletin No.: 07-08-44-007 Date: April 17, 2007 INFORMATION Subject: Information on Obtaining Replacement Navigation Discs When Radios are Exchanged Order Replacement Navigation Disc Through Navigation Disc Center Models: 2007 and Prior GM Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2007 and Prior Saab 9-7X with a Navigation Radio Attention: The purpose of this bulletin is to inform dealership personnel of a new procedure for obtaining a replacement navigation disc for radios that are sent to an ESC for exchange. This bulletin applies to U.S. and Canadian dealers only and is not intended for use by export dealers. When a navigation radio warranty exchange is performed, the customer must have a navigation disc to operate the new radio. If the customer's navigation disc was damaged or is stuck in the failed radio, the customer would have to wait for an excessive period of time for the disc to be returned or replaced. The Electronic Service Centers (ESC) are not authorized to remove stuck navigation discs from cores, as the cores must be returned to the supplier for analysis prior to any disassembly. The time it would take for the supplier to return the navigation disc would significantly delay the completion of the repair at the dealership. If the customer's navigation disc is damaged or cannot be removed from the radio, the dealership is to obtain an exchange radio through an ESC and a new navigation disc through the GM Navigation Disc Center. Both items can be shipped overnight to the dealership upon request. GM Navigation Disc Center Contact Information Via the web through gmnavdisc.com The GM Navigation Disc Center is also the center of expertise for navigation system questions. Warranty Information Include the part number and cost of the new navigation disc on the warranty claim for the navigation radio exchange. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-44-012E > Apr > 10 > Navigation System - Software/DVD Update Program > Page 8674 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 8679 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 8680 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 10037 > Apr > 10 > Campaign Unwanted Repeat Calls to OnStar(R) > Page 8681 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8690 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8691 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8692 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8693 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8694 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8695 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8696 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8697 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8698 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8699 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8700 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8701 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8702 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8703 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8704 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8705 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8706 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8707 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8708 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8709 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8710 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8711 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8712 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8713 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8714 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 09-08-46-001 > Apr > 09 > OnStar(R) Generation 6 Service Procedures > Page 8715 Circuit/System Testing Component Testing Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8720 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8721 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8722 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8723 Diagnostic Tips Review Table Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8724 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8725 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8726 Diagnostic Tips Review # 1 - Delphi Super Nav and Black Tie Nav Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8727 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8728 Diagnostic Tips Review # 2 - Delphi Legacy Navigation Radio Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8729 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8730 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8731 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8732 Diagnostic Tips Review # 3 - Denso Navigation Radios Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8733 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8734 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8735 Diagnostic Tips Review # 4 - Denso legacy Navigation Radio Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8736 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08-08-44-010F > Mar > 09 > Navigation Radio - Diagnostic Tips > Page 8737 Diagnostic Tips Review # 5 - Alpine Silver Box Navigation Radio Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8742 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8743 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8744 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8745 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8746 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8747 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8748 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8749 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8750 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8751 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8752 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8753 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8754 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8755 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8756 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8757 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8758 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8759 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8760 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8761 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8762 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8763 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8764 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8765 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8766 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8767 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8768 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8769 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8770 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8771 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8772 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8773 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8774 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 08089C > Nov > 08 > Campaign Deactivation Of Analog OnStar(R) > Page 8775 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8780 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8781 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8782 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8783 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8784 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8785 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8786 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8787 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8788 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8789 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8790 Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 05-08-46-006Q > Oct > 08 > OnStar(R) Analog/Digital Ready System Digital Upgrade > Page 8791 Labor Time Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Navigation System > Component Information > Technical Service Bulletins > All Other Service Bulletins for Navigation System: > 06-08-46-008C > Sep > 08 > OnStar(R) Analog/Digital System Information > Page 8796 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Police / Special Vehicle Options > System Information > Locations Left Front Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Police / Special Vehicle Options > System Information > Diagrams > Surveillance Mode Switch Surveillance Mode Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Police / Special Vehicle Options > System Information > Diagrams > Surveillance Mode Switch > Page 8818 Police / Special Vehicle Options: Diagrams Emergency Vehicle Rear Compartment Lid Lamp Emergency Vehicle Rear Compartment Lid Lamp-Left Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Police / Special Vehicle Options > System Information > Diagrams > Surveillance Mode Switch > Page 8819 Emergency Vehicle Rear Compartment Lid Lamp-Right Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Police / Special Vehicle Options > System Information > Diagrams > Surveillance Mode Switch > Page 8820 Police / Special Vehicle Options: Diagrams Emergency Vehicle Rear Window Panel Lamp Emergency Vehicle Rear Window Panel Lamp-Left Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Police / Special Vehicle Options > System Information > Diagrams > Surveillance Mode Switch > Page 8821 Emergency Vehicle Rear Window Panel Lamp-Right Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams Amplifier: Diagrams Audio Amplifier, C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 8826 Audio Amplifier, C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 8827 Audio Amplifier, C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 8828 Audio Amplifier, C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Diagrams > Page 8829 Amplifier: Service and Repair AMPLIFIER REPLACEMENT REMOVAL PROCEDURE 1. Remove the rear window trim panel. IMPORTANT: Inspect the retainers and the foam washers. Faulty retainers and washers must be replaced. 2. Disengage the amplifier retainers from the rear window panel. 3. Disconnect the electrical connectors from the amplifier. 4. Remove the amplifier. INSTALLATION PROCEDURE 1. Position the amplifier to the rear window panel. IMPORTANT: Make sure all of the foam washers are installed. Faulty retainers must be replaced. 2. Align the retainers to the openings in the rear window panel. Carefully push in the retainers in order to secure the amplifier. 3. Connect the electrical connectors to the amplifier. 4. Install the rear window trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation Compact Disc Player (CD): Description and Operation Cassette Features CASSETTE FEATURES Compact Disc Features COMPACT DISC FEATURES Each item in the list below represents topics covered in detail below. - AM/FM Reception - XM Reception - Antenna - Audio Amplifier - Theft Deterrent - Radio Data System (RDS) - XM Satellite Radio - XM Advisory Messages - Radio Chime Level Adjustment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Page 8833 - Steering Wheel Controls - Tape/CD Player Error Messages AM/FM RECEPTION Radio Signal The radio signal is sent from a broadcast station and is then received by an antenna. The strength of the signal received depends on the following: The power output, or wattage, of the broadcasting station - The location of the vehicle, or receiver, relative to the broadcast tower. - Obstacles between the tower and the receiver - Atmospheric conditions - Which band, AM or FM, the station is broadcasting - Type of antenna and the ground plane AM Reception The AM band has a lower frequency range than the FM band. These longer wavelengths: Bend around obstacles - Follow the curvature of the earth - May reflect, or skip, off the ionosphere The AM frequencies have longer range due to the ground wave. The ground wave follows the curvature of the earth and is affected by its conductivity. Greater conductivity equates to less signal loss, thus transmission over water is better than over land. The AM band has a range of 80-320 km (50-200 mi). FM Reception The shorter wavelengths of the higher frequency FM band: - Reflect off obstacles - Are absorbed by the ground - Penetrate the ionosphere Broadcasts in the FM band are limited to "line of sight" reception which is typically 40 km (25 mi). Even when out of a direct line of sight, the signal may be reflected into areas that would be in a "shadow" otherwise. Factors which affect the line of sight include: Height of the broadcast antenna - Height of the receiving antenna - Terrain and buildings in the broadcast path XM Reception XM satellite radio provides digital radio reception. The XM signal is broadcast from two satellites and, where necessary, terrestrial repeaters. The high power satellites allow the antenna to receive the XM signal even when foliage and other partial obstructions block the antennas view of the satellite. Terrestrial repeaters are used in dense urban areas. These repeaters will receive the satellite signal and re-broadcast them at much higher power levels in order to ensure reception in areas with densely packed tall buildings. Antenna The antenna is comprised of an active rear window antenna system. The radio sends the antenna enable signal to the radio antenna module which enables coupling of the IF signal from the rear window antenna grid to the radio. Audio Amplifier The purpose of an audio amplifier is to increase the power of a voltage or current signal. The output signal of an amplifier may consist of the same frequencies as the input signal or it may consist of only a portion of the frequencies of the input signal, as in the case of a subwoofer or a mid-range amplifier. Power is supplied to the audio amplifier via the RADIO fuse in the Junction Block-Right I/P. Ground is provided to the amplifier by G202. When the radio is turned on, the radio sends a voltage signal to the audio amplifier via the antenna enable circuit. This circuit enables the audio amplifier to amplify the speaker output circuits from the radio. The audio amplifier sends the speaker output signals to drive the appropriate speakers. Theft Deterrent The "Theftlock" theft deterrent system is a feature on all base and uplevel radios. There is no need to program a security code into the radio as in past model years. The theft deterrent system now utilizes class 2 serial data to determine if the radio is in the appropriate vehicle. Each time the radio receives the "run" power mode message, it compares the VIN information it has stored to the VIN information received from a module on the class 2 serial data circuit responsible for transmitting that information. If a mis-match occurs, the radio display will indicate to the user the radio is locked. Once this takes place, a DTC will set, the radio will not respond to any button presses and become inoperative. The two scenarios able to cause this condition are: A radio is installed from another vehicle. - A module which communicates on the class 2 serial data circuit which supplies VIN information to the radio is replaced and not properly setup with the correct VIN information for that vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Page 8834 The only way to unlock the radio is by using a scan tool. Always refer to the table to diagnose the "Theftlock" DTC for further information. Radio Data System (RDS) All uplevel audio systems are equipped with technology known as the Radio Data System (RDS). RDS is a system that sends data along with the audio of the FM station you are currently tuned to. RDS is a standard that defines how a FM broadcast station may send digital data along with the audio program. Think of it as a one way wireless modem, allowing the broadcaster to send information about the program to your receiver. RDS data is carried in what is known as a "subcarrier". A subcarrier is a frequency that the FM broadcaster is authorized to use to send data or other audio programs that are not audible in the main audio program. RDS information can be used to display program information and to control the radio. To receive the RDS signal, all that is needed is an FM receiver with an RDS circuit. A special integrated circuit capable of dealing with the RDS signal is in the RDS circuit and passes it along to the receiver's microprocessor where it is decoded and acted upon. RDS Basic Information RDS functions are provided in the FM broadcast band only. - RDS functions will only work with FM broadcast stations that are broadcasting RDS data. - Not all FM Broadcast stations broadcast RDS data or offer all of the RDS services. - RDS functions may not work properly when reception is weak, reception is of poor quality, or RDS is not implemented properly by the FM Broadcaster. In some cases, a radio station broadcasting incorrect information may cause the RDS features of the radio to appear to work improperly. Displaying RDS Information The RDS feature is always on. When tuned to a non-RDS station, the radio will display frequency information as you would normally expect. When tuned to an RDS station, the radio can operate as follows: The radio will change from displaying the frequency of the FM station to displaying the call letters of the station or display the nickname of the station. - Display the type of program. - Display general information such as artist and song title, call in phone numbers, etc. Viewing and Selecting RDS Information for Display Press the TUNE knob once for less than 2 seconds when the radio displays the program service (PS) name and the frequency of the station will be displayed. Press the knob again, and the program type (P-Type) will be displayed. Pressed again, and the program type (PTY) name will be displayed, if the broadcaster is broadcasting one. The PTY name is an eight-character name that the broadcaster may use to further identify the type of programming currently being broadcast. Should you decide that Frequency, P-Type or PTY name is more desirable to display when tuned to an RDS station than the PS name, press the TUNE knob until the desired information is displayed, then press and hold for more than 2 seconds. A beep should be heard and the radio will now display the selected information whenever tuned to an RDS broadcaster. The radio will display frequency for all non-RDS broadcast stations. Using RDS Program Types to Tune Radio Listed are several ways on how to tune your radio using RDS program types. The radio will now be configured to tune based on RDS data rather than frequency. A Fast Way to Find a RDS Station In Your Listening Area 1. Press the PROG TYPE or P-TYPE button, the radio displays the current P-Type to search for. 2. Rotate the TUNE SELECT RCL knob until the radio displays "ANY TYPE". Press the SEEK SCAN button again and the radio will now seek the first RDS Broadcaster of any kind that it can find in the FM band. Finding a RDS Station By Specific Program Type 1. Press the PROG TYPE or P-TYPE button, the radio will display the current P-Type to search for. 2. Rotate the TUNE SELECT RCL knob until the desired program type is shown in the display. 3. Press the SEEK SCAN button and the radio will now seek the first RDS Broadcaster of the selected P-Type. If the radio cannot find the desired P-Type, the radio displays "NOT FOUND" and will return to the last station you were listening to. Using the INFO Feature When the INFO icon appears in the radio display, a new text message is available for viewing. These text messages are from the RDS broadcaster to the listening public and may be general information such as artist and song title, call in phone numbers, etc. How to View the INFO Message To view the message when the INFO icon appears, press the INFO button to display the text message. If you do not press the INFO button again, the text message will automatically be displayed 8 characters at a time, 3 seconds between updates. - To view the text message faster, press the INFO button for less than 1 second to scroll through the message at your own speed. - The INFO icon disappears as soon as you press the INFO button. The INFO icon will appear when a new different message is received. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Page 8835 - To view the most recent received message, press the INFO icon at any time, even if the icon does not appear in the display. Controlling the Radio RDS can control the radio when data the receiver can use responds to timely information performing the following: Interrupt the playback of your cassette or CD for traffic or emergency bulletins. - Search for stations by type of program. - Automatically follow networked programming from transmitter to transmitter as you travel from one listening area to another. - Set your clock to the time that the RDS broadcast station broadcasts. Using the RDS Traffic Feature Some RDS broadcasters may carry traffic information programming to inform you of current traffic conditions in your listening area and is indicated by the TRAF icon in the radio display. RDS enables the broadcaster to get this information to you even when you are listening to a tape or compact disc. This feature can be enabled or disabled by the listener. Press the TRAF button to find a station that claims to carry traffic information. You may do this even when playing a cassette tape or compact disc. This action will operate in the background without interrupting the current playback. If the radio is not currently tuned to an RDS traffic station, the radio will immediately seek an RDS traffic station. If the radio finds an RDS traffic station, the "TRAF" icon will appear on the radio display as will brackets around the [TRAF] icon. If the radio cannot find an RDS traffic station after searching through the entire FM band, the radio will display "NO TRAFFIC". Traffic Interrupt Feature Whenever the TRAF icon is displayed, the current FM station may also broadcast traffic announcements. Traffic announcements are reports of the current traffic conditions in the listening area of the tuned FM broadcasters. Your radio can interrupt the playback of a cassette or compact disc by use of the traffic interrupt feature. The traffic interrupt feature is enabled when the TRAF icon is displayed. If the broadcaster sends out a traffic announcement while you are listening to FM or in the playback mode, "TRAFFIC" will be displayed on the radio and the audio from the broadcaster will be heard. At the conclusion of the traffic announcement, the radio will return to the previous playback mode. During the time the radio displays "TRAFFIC", you can adjust the volume of the traffic announcement. This will be the volume at which all future traffic announcements will be heard until the volume during another traffic announcement. You can also interrupt a traffic announcement interrupt by pressing the TRAF button. RDS Program Type Interrupts When the Program Type feature is on, all program types may be selected as interrupts. Perform the following to select a program type as an interrupt. 1. Turn ON the radio. 2. Select the program type. 3. Press and hold the program type button, labeled PROG TYPE or P-TYPE, for 2 seconds while the program type is displayed. When an interrupt is set, the display shows the program type followed by an asterisk and the brackets around the [P-TYPE] icon are illuminated. To turn an interrupt off: 1. Select a program type marked as an interrupt. 2. Press and hold the program type button, labeled PROG TYPE or P-TYPE, for 2 seconds. The program type will be unmarked by turning off the asterisk. If no other program type interrupts are set, the brackets around the [P-TYPE] icon are also turned off. When a Program Type Interrupt is set, the radio will wait for the current FM RDS station to change its program type to one of those selected as an interrupt. When the station program type changes to a program type interrupt setting then the interrupt is activated. If the radio is in a playback mode, an interrupt will cause the radio to switch to the FM band, display the program type followed by "INT", and adjust the volume to the last active interrupt volume. If the radio is in the FM mode when an interrupt occurs, only the volume will change. The radio resumes the mode that was active prior to the interrupt, when an interrupt ends. An interrupt in progress may be canceled by pressing the program type button or a mode button. During a national or local emergency, a special program type interrupt message "ALERT!" is displayed. This special announcement will cancel all other RDS features that are in progress, such as a traffic announcement. Alternate Frequency (AF) Switching RDS permits broadcaster's to send information to the radio that allows the radio to automatically switch frequency to the best quality station in that broadcaster's network. Since the radio is displaying the broadcaster call letters or nickname, the listener will not see the frequency during an AF switch unless you have changed the default display to be frequency instead of Program Service name. To enable or disable AF switching perform the following: Press and hold the AM/FM or BAND button for two seconds or more. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Page 8836 - The radio will display "AF ON" or "AF OFF" depending on the current condition of AF and a confirmation beep will be heard. When AF is enabled and you recall an RDS station stored on preset, the radio determines if the station stored is of acceptable quality. If not, the radio checks all available AF's for your station. If the radio fails to locate your program, "AF SEARCH" will be displayed as the radio scans across the band looking for your program or an affiliated network. If the radio cannot find the original station or an acceptable alternate frequency "NOT FOUND" will be displayed and the radio returns to the original frequency for the preset. RDS Clock Time Broadcasters can choose to send clock time information in the RDS data. This information can be used to update the clock time on the radio. RDS clock time is broadcasted once a minute. To set the clock using RDS clock data perform the following: Press and hold the HR and MIN buttons together for two or more seconds to update the time. - The display will show "UPDATED" after receiving the broadcasted time data. - If the broadcaster is not broadcasting the time data, the radio will display "NO UPDATE" and the time remains unchanged. XM Satellite Radio XM is a national satellite radio service that offers up to 100 coast to coast channels including music, news, sports, talk and children's programming. XM provides digital quality audio and text information, including song title and artist name. A service fee is required in order to receive the XM service. For more information, contact XM at www.xmradio.com or call 1-800-852-9696. Digital Radio Receiver The radio controls communicate with the digital radio receiver via the class 2 communication circuit. The digital radio receiver sends remote radio audio signals to the radio. Viewing Messages Press the DISP or RCL button while in XM mode to view various pieces of information related to the current song or channel. By pressing and releasing the DISP or RCL button, you may view four different categories of information: Artist Name/Feature, Song/Program Title, Channel Category, and other Additional Information that may be broadcast on that channel. Additional Information messages may not always be available. If an Additional Information message is being broadcast on the tuned channel, the INFO icon will appear on the display. Each of the four information types may have multiple pages of text. To reach a category, press and release the DISP or RCL button consecutively until the desired type is displayed. If there are multiple pages of text for the selected information type, the radio will automatically display all the pages for that type at a rate of approximately one page every three seconds before timing out and returning to the default display. You may override this feature by pressing the DISP or RCL button to review all of the pages at your own pace. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Page 8837 XM Advisory Messages XM Advisory Messages Radio Chime Level Adjustment IMPORTANT: Radio chime level adjustment is only available on radios equipped with RDS. The radio is the vehicle chime producer. The chime is audible from the driver's side front door speakers. To adjust the chime level louder. 1. Turn ON the ignition. 2. Turn OFF the radio. 3. Press and hold preset button 6. The chime volume level will change from the normal level to loud. The radio displays "LOUD". To change back to the default or normal setting follow the previous steps. The chime volume level will change from the loud level to normal. The radio displays "NORMAL". Each time the chime volume is changed, the radio sounds three chimes as an example of the new volume selected. Steering Wheel Controls Some audio functions are available using the steering wheel controls. The steering wheel controls are actually a resistor network that consists of multiple momentary contact switches and a series of resistors. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network, which produces a specific voltage value unique to the switch selected. These specific voltage values allow the radio to identify which switch has been pressed. The radio supplies voltage to the steering wheel control switch via the radio on signal circuit. The specific voltage signal from the switch is returned to Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Description and Operation > Page 8838 the radio on the steering wheel controls signal circuit. Tape/CD Player Error Messages The radio displays an error when any of the following occurs. The radio will display error codes for the tape player and integral CD player. - The radio will display the following tape player error codes for tight tape, broken tape, and wrapped tape. If these conditions are detected, the radio will switch to the radio mode and eject the tape. The error code will be displayed for 5 seconds, followed by the tuner display, then the default. E10 or TIGHT TAPE-Tight tape - E11 or BROKEN TAPE-Broken tape - E14 or WRAPPED TAPE-Wrapped tape - The radio will display the following integral CD player error codes. If one of these problems is detected, the unit will switch to the radio mode and eject the CD. The display will show TOD, if the unit is off, or display the radio frequency for 5 seconds, then the default, if the unit is on. E20 or CHECK CD-Optics focus error, maybe due to moisture - E21 or CHECK CD-Optics loss of tracking control, maybe due to blemishes on disc - E22 or PLAYER ERR-Load/Unload motor problem - E23 or PLAYER ERR-Communication problem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams Speaker: Diagrams Speaker - LF Door Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 8847 Speaker - RF Door Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 8848 Speaker - LR Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Diagrams > Page 8849 Speaker - RR Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement Reference Speaker Replacement Reference Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement Reference > Page 8852 Speaker: Service and Repair Speaker Replacement - Front Door SPEAKER REPLACEMENT - FRONT DOOR REMOVAL PROCEDURE 1. Remove the front door trim panel. IMPORTANT: The speakers are to be replaced as a set. 2. Remove the screws from both speakers. 3. Disconnect the electrical connector from the speaker housing. 4. Remove the speakers. INSTALLATION PROCEDURE 1. Connect the electrical connector to the speaker. Position the speaker to the door. 2. Install the speakers. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the speaker screws. Tighten Tighten the speaker screws to 2 N.m (18 lb in). IMPORTANT: Due to the lower trim fasteners close proximity to the speaker cone, the door trim must be installed with care. 4. Install the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement Reference > Page 8853 Speaker: Service and Repair Speaker Replacement - Rear SPEAKER REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the rear window trim panel. 2. Disengage the speaker retaining tabs. Remove the speaker alignment tab from the opening in the rear window panel. The speaker seal may have bonded with the shelf metal. Carefully pry the housing away from the metal while holding the speaker retaining tabs in order to remove the speaker. 3. Remove the rear speaker. 4. Disconnect the electrical connector from the rear speaker. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement Reference > Page 8854 1. Connect the electrical connector to the rear speaker. Position the rear speaker to the rear window panel. 2. Install the speaker alignment tab into the opening in the rear window panel. Engage the speaker retaining tabs. 3. Install the rear window trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Service and Repair > Speaker Replacement Reference > Page 8855 Speaker: Service and Repair Speaker Grille Replacement - Rear SPEAKER GRILLE REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the rear window shelf trim panel. 2. Remove the nuts from the rear speaker grille. 3. Release the rear speaker grille retainer tabs in order to remove the grille from the rear window trim panel. INSTALLATION PROCEDURE 1. Align the rear speaker grille to the rear window trim panel. 2. Install the rear speaker grille to the rear window trim panel pressing into place until the retainer tabs are fully seated. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the nuts to the rear speaker grille. Tighten Tighten the speaker grille nuts to 2 N.m (18 lb in). 4. Install the rear window shelf trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Description and Operation Cassette Features Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Description and Operation > Page 8859 Tape Player: Service and Repair CASSETTE PLAYER CARE AND CLEANING TOOLS REQUIRED J 39916-A CD and Cassette Diagnostic Audio Kit Follow the recommended cleaning schedule: 1. Clean the cassette player every 15 hours for the best performance. 2. Clean the cassette player every 50 hours in order to prevent damage to the tape head. Clean the following 2 parts on the tape player: The head - The capstan Leave the tape player in the vehicle, since you can reach the parts through the tape door. Perform this service at least every 50 hours of cassette operation. After 50 hours of tape play, CAN (Clean) appears on the display as a reminder. Although the system will still function when this message is displayed, the following conditions may occur until the head and the capstan are cleaned: - Reduced sound quality - Damage to the cassette tapes After cleaning the cassette tape player, press and hold EJECT for 5 seconds in order to reset the CAN indicator. The radio displays - - - in order to show that the clean feature has been reset. Failure to clean the cassette player regularly may cause the following conditions: - Reduced sound quality - Damage to the cassettes - Damage to the mechanism Keep the cassette tapes correctly stored in their plastic cases away from the following conditions: - Contaminants - Direct sunlight - Extreme heat Failure to correctly store the cassette tapes may cause the following conditions: - Improper operation of the cassette tapes - Premature failure of the tape player The cassettes are subject to wear. The sound quality may degrade over time. Before servicing a tape player, verify that the following conditions exist: - The cassette tape is in good condition. - The tape player is clean. Clean the tape player at least after every 50 hours of use in order to provide optimum performance. The radio displays CAN as a reminder every 50 hours. If a reduction in the sound quality occurs, regardless of when the tape player was last cleaned, play a different cassette tape in order to see if the tape or the tape player is at fault. If the second cassette tape results in no improvement in sound quality, clean the tape player. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Description and Operation > Page 8860 Use a scrubbing action, non-abrasive cleaning cassette (part of J 39916-A) for proper tape player cleaning. This cleaner is a wet-type cleaning system. The wet-type cleaning system uses a cleaning cassette with pads. The pads scrub the tape head as the hubs of the cleaner cassette turn. If you use this type of cleaner, the following conditions may occur: - The radio displays an error. - The cartridge ejects. These conditions are normal and is the result of an added feature in the tape player that detects broken tapes. If an error occurs, insert the cleaning cassette at least 3 times in order to thoroughly clean the tape player. The following steps will enable the radio to accept the tape: 1. Press and hold the Tape/CD button for 5 seconds. 2. Radio will display READY. 3. Insert cleaner. 4. Press and hold Eject button to reset CAN. You can also use a non-scrubbing action, wet-type cleaner. This type of cleaner uses a cassette with a fabric belt which cleans the tape head. This type of cleaning cassette will not cause an error, but may not clean the tape player as thoroughly as the scrubbing type cleaner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions Accessory Delay Module: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8866 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8867 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8868 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8869 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8870 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8871 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8872 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8873 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8874 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8875 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8876 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8877 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8878 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8879 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8880 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8881 Accessory Delay Module: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8882 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8883 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8884 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8885 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8886 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8887 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8888 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8889 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8890 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8891 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8892 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8893 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8894 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8895 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8896 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8897 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8898 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8899 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8900 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8901 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8902 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8903 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8904 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8905 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8906 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8907 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8908 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8909 Accessory Delay Module: Electrical Diagrams Retained Accessory Power (RAP) Diagram 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 8910 Retained Accessory Power (RAP) Diagram 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Diagrams > Page 8911 Accessory Delay Module: Description and Operation RETAINED ACCESSORY POWER (RAP) DESCRIPTION AND OPERATION SERIAL DATA CONTROL OF RETAINED ACCESSORY POWER (RAP) Retained accessory power (RAP) is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its shut-off limit. The modules listed below all receive a RAP message from the body control module (BCM) over the serial data circuits. The BCM monitors the ignition switch position, battery condition and passenger compartment door status to determine whether RAP should be initiated. The BCM then sends a message to the listed modules telling them that they are in RAP power mode. The modules then support the operation of the systems under their control as required by their RAP power mode strategy. RAP will end when 1 of the following conditions are met: The BCM receives an input, as a hard wired input from the door switches, indicating the opening of a passenger compartment door. - The BCM receives a message from its internal timer indicating the end of the RAP period after 10 minutes. - The BCM detects a decrease in battery capacity below a prescribed limit. - The transition from OFF to RUN/ON or ACC of the ignition switch. The BCM then sends a serial data message to the listed devices ending the RAP function. The devices receiving serial data messages for RAP functions are: Auxiliary power drop connector - Driver information center (DIC) - Instrument panel cluster (IPC) - Radio - Remote CD player, if equipped - Vehicle interface unit (VIU), if equipped RELAY CONTROL OF RETAINED ACCESSORY POWER (RAP) RAP is a vehicle power mode that permits the operation of selected customer convenience items after the ignition switch is turned OFF. These selected items will remain in operation until a passenger compartment door is opened or until the RAP function timer reaches its shut-off limit. The BCM closes the RAP relay in either the RAP function as described above or if the BCM detects a RUN/ON or accessory power mode. This provides power for the following: The power windows - The sunroof control module, if equipped The BCM opens the RAP relay to end the RAP function when it ends the RAP function as outlined in the previous text. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Accessory Delay Module: Initial Inspection and Diagnostic Overview Diagnostic Starting Point DIAGNOSTIC STARTING POINT - ACCESSORY DELAY MODULE Begin the system diagnosis with a Diagnostic System Check - Accessory Delay Module. The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check DIAGNOSTIC SYSTEM CHECK - ACCESSORY DELAY MODULE TEST DESCRIPTION The numbers below refer to the step numbers on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. The presence of DTCs which begin with U indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. TEST Steps 1 - 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8914 Steps 4 - 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8915 Accessory Delay Module: Symptom Related Diagnostic Procedures A Symptoms SYMPTOMS - ACCESSORY DELAY MODULE IMPORTANT: Review the system operation in order to familiarize yourself with the system functions. Refer to Retained Accessory Power (RAP) Description and Operation. Visual/Physical Inspection Inspect for aftermarket devices which may affect the operation of the retained accessory power system. - Inspect the easily accessible or visible system components for obvious damage or conditions which may cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Retained Accessory Power (RAP) On After Timeout - Retained Accessory Power (RAP) Inoperative. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8916 Steps 1 - 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8917 Steps 10 - 11 Steps 1 - 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8918 Steps 4 - 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8919 Accessory Delay Module: Scan Tool Testing and Procedures Scan Tool Data Definitions SCAN TOOL DATA DEFINITIONS Software Part Number: Part number of component program or the ECU. Used to determine applicability to vehicle RPO content. Accessory Switch: Input from ignition switch Accessory circuit. Used to determine power mode. Hot in ACCESSORY and RUN. Driver Door Open Sw.: Input from the driver door indicating door status (Open-Closed). Door Ajar Switches: Input showing state of the passenger door(s). Doors Battery Fd: Indicates completion of the power circuit for the door control functions. Doors System Gnd: Indicates the completion state of the ground circuit for the door functions. Electronics Battery Fd: Data indicates the voltage detected by the control module on the power circuit for the module internal devices. Electronics Battery Fd: Input indicates the completion state of the power circuit for the module internal devices. Electronics System Gnd: Indicates the completion state of the ground circuit for the module internal devices. Ignition 0: Input to the control module from the ignition switch indicating the Ignition 0 position. Switch closed (HOT) in ignition switch positions Unlock, Accessory, Run, Crank. Ignition 1: Input to the control module from the ignition switch indicating the Ignition 1 position. Switch closed (HOT) in ignition switch positions Run, Crank. Inadvertent Power Output: Input indicating the sensed state of the inadvertent power request circuit. Inadvertent Power Relay: Output indicating the state as commanded by the control module. Lamp Request: Input telling the control module to initiate inadvertent power management. Load Management Status: Output indicating the power mode commanded. Loads Battery Fd: Indicates the completion state of the supply circuit for the high current loads. Loads System Gnd: Indicates completion state of the ground circuit for the high current loads. Pass Door Jamb Sw.: Input showing the state of the front passenger door. RAP Relay: Output indicates state that the control module has commanded. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Accessory Delay Module > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8920 Scan Tool Data List Scan Tool Output Controls Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > Customer Interest for Antenna Control Module: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception Antenna Control Module: Customer Interest Audio System - Static/Poor Radio Reception Bulletin No.: 05-08-44-008A Date: June 17, 2005 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Static, Poor and/or No AM/FM Radio Reception In Police Package Equipped Vehicles (Replace Radio Antenna Module) Models: 2004-2005 Chevrolet Impala Built After VIN Breakpoint 49302036 with Police Package (RPO 9C1) Supercede: This bulletin is being revised to include Diagnostic and Repair Information, remove an RPO code and include a VIN breakpoint. Please discard Corporate Bulletin Number 05-08-44-008 (Section 08 - Body and Accessories). Condition Some customers may comment that certain police package vehicles equipped with radio communication equipment may experience poor AM/FM radio reception, no radio reception and/or static through the radio system. Cause Police package vehicles radio communication equipment may overload the radio AM/FM radio antenna module. Diagnosis To ensure the radio antenna module is the cause of the poor reception, refer to Radio Poor Reception (SI Document ID # 782713). Correction If diagnosis leads to a suspect radio antenna module, replace the Radio Antenna Module. Refer to Antenna Module Replacement (SI Document ID # 1515377). Dealer Action Contact customers that were told they would be notified when this repair became available. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > Customer Interest for Antenna Control Module: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception > Page 8929 Parts Parts will be available for dealer ordering on June 20, 2005. Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna Control Module: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception Antenna Control Module: All Technical Service Bulletins Audio System - Static/Poor Radio Reception Bulletin No.: 05-08-44-008A Date: June 17, 2005 ADVANCE SERVICE INFORMATION RESOLUTION Subject: Static, Poor and/or No AM/FM Radio Reception In Police Package Equipped Vehicles (Replace Radio Antenna Module) Models: 2004-2005 Chevrolet Impala Built After VIN Breakpoint 49302036 with Police Package (RPO 9C1) Supercede: This bulletin is being revised to include Diagnostic and Repair Information, remove an RPO code and include a VIN breakpoint. Please discard Corporate Bulletin Number 05-08-44-008 (Section 08 - Body and Accessories). Condition Some customers may comment that certain police package vehicles equipped with radio communication equipment may experience poor AM/FM radio reception, no radio reception and/or static through the radio system. Cause Police package vehicles radio communication equipment may overload the radio AM/FM radio antenna module. Diagnosis To ensure the radio antenna module is the cause of the poor reception, refer to Radio Poor Reception (SI Document ID # 782713). Correction If diagnosis leads to a suspect radio antenna module, replace the Radio Antenna Module. Refer to Antenna Module Replacement (SI Document ID # 1515377). Dealer Action Contact customers that were told they would be notified when this repair became available. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna Control Module: > 05-08-44-008A > Jun > 05 > Audio System - Static/Poor Radio Reception > Page 8935 Parts Parts will be available for dealer ordering on June 20, 2005. Warranty Information For vehicle repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > Page 8936 Antenna Control Module: Locations Left Side Of Rear Window Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > Page 8937 Left Side Of Rear Window Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > Page 8938 Radio Antenna Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > Page 8939 Antenna Control Module: Service and Repair ANTENNA MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the upper trim panel from the left rear quarter. 2. Disconnect the antenna amplifier electrical connector and the antenna coaxial cable. The antenna coaxial cable uses a sliding snap-lock. Pull the lock in order to remove the antenna coaxial cable. 3. Detach the black antenna leads from the glass. The upper lead is held to the body metal with a wiring clip. Carefully pry the clip out of the metal. 4. Remove the antenna amplifier bolt. 5. Remove the antenna amplifier. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Position the antenna amplifier to the inner upper panel of the left rear window. Install the antenna amplifier bolt. Tighten Tighten the bolt to 3 N.m (27 lb in). IMPORTANT: The antenna coaxial cable uses a sliding snap-lock. Holding the sliding lock feature will prevent installation. 2. Connect the antenna amplifier electrical connectors: 2.1. Position the antenna coaxial cable behind the sliding lock feature. 2.2. Install the antenna coaxial cable to the sliding lock feature. IMPORTANT: If the wiring clip is faulty, replace the wiring clip prior to installation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antenna Control Module > Component Information > Technical Service Bulletins > Page 8940 3. Install the antenna leads to the rear window terminals. Push the wiring clip on the upper lead into the hex hole in the metal. 4. Install the upper trim panel at the left rear quarter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 8949 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 8950 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > Recalls for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 8951 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) Technical Service Bulletin # 10037 Date: 100420 Campaign - Unwanted Repeat Calls to OnStar(R) CUSTOMER SATISFACTION Bulletin No.: 10037 Date: April 20, 2010 Subject: 10037 - Unwanted Repeat Calls to OnStar(R) Models: 2003 Buick LeSabre 2004-2006 Buick Rendezvous 2005 Buick LeSabre, Terraza 2005-2006 Buick LaCrosse/Allure 2006-2008 Buick Lucerne 2008 Buick LaCrosse/Allure 2008-2009 Buick Enclave 2003 Cadillac CTS 2004 Cadillac Escalade 2004-2005 Cadillac CTS-V, Deville 2005 Cadillac Escalade ESV, SRX 2005-2006 Cadillac STS 2005-2008 Cadillac CTS 2006-2008 Cadillac DTS 2007 Cadillac Escalade, Escalade EXT 2007-2008 Cadillac Escalade ESV 2008 Cadillac SRX, STS 2002 Chevrolet Impala 2003-2008 Chevrolet Suburban 2003-2009 Chevrolet Silverado 2004-2008 Chevrolet Impala 2005 Chevrolet Colorado, Corvette, Malibu 2005-2006 Chevrolet Uplander 2005-2008 Chevrolet Avalanche, Tahoe, TrailBlazer 2006 Chevrolet HHR, Monte Carlo 2006-2008 Chevrolet Equinox 2007-2008 Chevrolet Corvette 2008 Chevrolet HHR 2008-2009 Chevrolet Cobalt, Colorado, Malibu, Uplander 2003 GMC Envoy XL, Sierra, Yukon XL 2004-2008 GMC Yukon 2005-2009 GMC Sierra 2005-2008 GMC Yukon XL 2006-2008 GMC Envoy 2007 GMC Canyon 2007-2009 GMC Acadia 2006 HUMMER H2 2006-2008 HUMMER H3 2008 HUMMER H2 2003 Oldsmobile Silhouette 2005 Montana SV6 2005-2008 Pontiac Grand Prix 2006 Pontiac G6, Vibe 2007 Pontiac Montana SV6 2007-2008 Pontiac Solstice 2008 Pontiac G6, Torrent 2008-2009 Pontiac G5, G8 2009 Pontiac G3, Montana SV6 2005-2007 Saturn ION 2006-2009Saturn VUE 2007-2008 Saturn AURA, OUTLOOK, SKY Equipped with OnStar(R) (RPO UE1) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 8957 THIS PROGRAM IS IN EFFECT UNTIL APRIL 30, 2011. Condition Certain 2002-2009 model year vehicles equipped with OnStar(R) may have a condition in which the vehicle's OnStar(R) system repeatedly makes incomplete calls to OnStar(R) without the vehicle's occupant(s) input or knowledge. Customer initiated Blue Button call, Emergency calls, and Automatic Crash Notification calls will also fail to establish a data connection with the OnStar(R) Call Center. Eventually, the customer's call will connect as a voice only line and the customer will be able to talk with an OnStar(R) advisor; however, the advisor will not get crucial customer data such as vehicle identification and location. Correction Dealers/retailers are to replace the OnStar(R) module (VCIM). Vehicles Involved Involved are certain 2002-2009 model year vehicles equipped with OnStar(R), and built within these VIN breakpoints: Note: Some model years/models have only one vehicle involved. Important Dealers/retailers are to confirm vehicle eligibility prior to beginning repairs by using GMVIS (dealers/retailers using WINS) or the Investigate Vehicle History link (dealers/retailers using GWM). Not all vehicles within the above breakpoints may be involved. For dealers/retailers with involved vehicles, a listing with involved vehicles containing the complete vehicle identification number, customer name, and address information has been prepared and will be provided to dealers/retailers through the GM GlobalConnect Recall Reports. Dealers/retailers will not have a report available if they have no involved vehicles currently assigned. The listing may contain customer names and addresses obtained from Motor Vehicle Registration Records. The use of such motor vehicle registration data for any purpose other than follow-up necessary to complete this program is a violation of law in several states/provinces/countries. Accordingly, you are urged to limit the use of this report to the follow-up necessary to complete this program. Parts Information US: OnStar(R) modules required for this program are to be obtained by contacting Autocraft Electronics via the web at www.autocraft.com, and selecting the catalog item that contains bulletin number 10037 (or PIC 4893B), or by calling 1-800-336-3998. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. Canada: OnStar(R) modules required for this program are to be obtained by contacting MASS Electronics at 1-877-410-6277. Dealer must provide the VIN, R.O. number, and the current vehicle mileage. DO NOT ORDER ONSTAR(R) MODULES FROM GENERAL MOTORS CUSTOMER CARE AND AFTERSALES (GMCC&A;), SATURN SERVICE PARTS OPERATION (SSPO), OR THE TECHNICAL ASSISTANCE CENTER (TAC). Courtesy Transportation The General Motors Courtesy Transportation program is intended to minimize customer inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited Warranties. The availability of courtesy transportation to customers whose vehicles are within the warranty coverage period and involved in a product program is very important in maintaining customer satisfaction. Dealers/retailers are to ensure that these customers understand that shuttle service or some other form of courtesy transportation is available and will be provided at no charge. Dealers should refer to the General Motors Service Policies and Procedures Manual for Courtesy Transportation guidelines. Claim Information 1. Submit a claim using the table below. 2. Courtesy Transportation - For dealers/retailers using WINS, submit using normal labor code; for dealers/retailers using GWM - submit as Net Item under the repair labor code. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 8958 * Dealers using WINs: Add 0.2 hours to the labor time for administrative allowance for the module exchange. Dealers using GWM: Submit 0.2 hours administrative allowance under "Administration Time" for the module exchange. ** The $25 represents the additional net amount allowed for the module exchange. *** Dealers are to claim only administrative allowance of 0.2 hours when the module is replaced by Masscomp's Mobile Unit. Dealers using WINS should submit the 0.2 hours administrative allowance in labor time. Dealer using GWM should submit the 0.2 hours administrative allowance under Administrative Time. Customer Notification OnStar will notify customers of this program on their vehicle. Dealer Program Responsibility All unsold new vehicles in dealers'/retailers' possession and subject to this program must be held and inspected/repaired per the service procedure of this program bulletin before customers take possession of these vehicles. Dealers/retailers are to service all vehicles subject to this program at no charge to customers, regardless of mileage, age of vehicle, or ownership, through April 30, 2011. Customers who have recently purchased vehicles sold from your vehicle inventory, and for which there is no customer information indicated on the dealer/retailer listing, are to be contacted by the dealer/retailer. Arrangements are to be made to make the required correction according to the instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin for your use in contacting customers. Program follow-up cards should not be used for this purpose, since the customer may not as yet have received the notification letter. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Communications Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Communications Control Module: > 10037 > Apr > 10 > Campaign - Unwanted Repeat Calls to OnStar(R) > Page 8959 In summary, whenever a vehicle subject to this program enters your vehicle inventory, or is in your dealership/facility for service through April 30, 2011, you must take the steps necessary to be sure the program correction has been made before selling or releasing the vehicle. Disclaimer Service Procedure Service Procedure Note Do NOT replace the inside rear view mirror in tandem with this concern. The mirror has no bearing on this specific issue. 1. Remove the OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module removal instructions. Note Inform customer that all Bluetooth devices must be paired with the new VCIM. Bluetooth devices that have not been paired to the new VCIM will not function properly. 2. Install the new OnStar(R) module (referred to as the Communication Interface Module (CIM) or Vehicle Communication Interface Module (VCIM) in SI). Refer to SI for module installation instructions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8968 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8969 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8970 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8971 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8972 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8973 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8974 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8975 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8976 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8977 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8978 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8979 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8980 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8981 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8982 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8983 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8984 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8985 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8986 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8987 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8988 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8989 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8990 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8991 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8992 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8993 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8994 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8995 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8996 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8997 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8998 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 8999 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9000 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Recalls: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9001 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: Customer Interest OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 9007 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: Customer Interest OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 9012 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: Customer Interest OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 9017 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: Customer Interest OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 9022 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > Customer Interest: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 9023 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 9029 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9038 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9039 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9040 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9041 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9042 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9043 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9044 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9045 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9046 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9047 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9048 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9049 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9050 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9051 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9052 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9053 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9054 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9055 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9056 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9057 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9058 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9059 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9060 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9061 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9062 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9063 Circuit/System Testing Component Testing Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9068 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9069 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9070 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9071 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9072 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9073 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9074 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9075 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9076 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9077 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9078 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9079 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9080 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9081 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9082 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9083 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9084 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9085 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9086 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9087 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9088 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9089 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9090 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9091 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9092 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9093 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9094 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9095 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9096 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9097 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9098 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9099 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9100 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9101 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9106 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9107 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9108 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9109 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9110 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9111 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9112 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9113 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9114 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9115 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9116 Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9117 Labor Time Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 9122 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 9131 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 9140 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 9145 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 9146 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Number Incorrect/Incorrectly Assigned INFORMATION Bulletin No.: 05-08-46-004C Date: December 23, 2010 Subject: OnStar(R) Phone Number Concerns (Phone Number Incorrect/Assigned to Another Vehicle/Phone) That Occur During Diagnosis of OnStar(R) System Models: 2000-2011 GM Passenger Cars and Trucks Equipped with OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to update model years up to 2011. Please discard Corporate Bulletin Number 05-08-46-004B (Section 08 - Body and Accessories). During diagnosis of an OnStar(R) concern, the technician may be told that the OnStar(R) phone number is incorrect or tied to another vehicle and/or phone of some kind. To resolve these concerns, the Tech 2(R) with software version 22.005 (or higher), has the capability to change the OnStar(R) phone number. Service Procedure 1. With the Tech 2(R), build the vehicle to specifications within the Diagnostics area of the Tech 2(R). 2. For vehicles with physical-based diagnostics - under Body, go to the OnStar(R) section. Then select the Special Functions menu. For vehicles with functional-based diagnostics - under Body and Accessories, go to the Cellular Communication section. Select Module Setup and then Vehicle Communication Interface Module. 3. Locate the Program Phone Number prompt and select it. The original phone number will be displayed on the Tech 2(R) screen. 4. Contact the OnStar(R) team at the GM Technical Assistance Center (TAC) to obtain a new phone number. 5. Highlight the digits of the phone number one at a time and enter the new phone number using the number keys on the Tech 2(R). 6. Press the Soft key at the base of the screen for Done once these numbers have been changed on the screen. 7. Press the Soft key for Done again. The area code or new phone number has now been programmed into the phone. 8. Cycle the ignition to Off and open the driver's door. 9. Press the blue OnStar(R) button to make sure that a normal connection can be made to the OnStar(R) call center. If applicable, make sure the Hands-Free Calling (HFC) works properly by making a phone call. 10. If the system is working properly, fax or voicemail a case closing into the OnStar(R) team at TAC with the results. Dealers in Canada should submit case closing information through the GM infoNET. Please follow this diagnostic process thoroughly and complete each step. If the condition exhibited is resolved WITHOUT completing every step, the remaining steps do not need to be performed. If the procedure above does not resolve the condition, you must contact TAC for further assistance. This diagnostic approach was developed specifically for this condition and should not automatically be used for other vehicles with similar symptoms. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use: Warranty Information (Saab Models) For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-004C > Dec > 10 > OnStar(R) - Number Incorrect/Incorrectly Assigned > Page 9152 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-44-007D > May > 09 > OnStar(R) - Negative Impact of Cloth/Vinyl Roofs Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Negative Impact of Cloth/Vinyl Roofs INFORMATION Bulletin No.: 02-08-44-007D Date: May 12, 2009 Subject: Negative Impact of Dealer-Installed Cloth/Vinyl Roofs on XM Radio and/or OnStar(R) Systems Models: 2002-2009 Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X with XM Radio (RPO U2K) and/or OnStar(R) (RPO UE1) .............................................................................................................................................................. .................................................................................. Supercede: This bulletin is being revised to include the 2009 model year. Please discard Corporate Bulletin Number 02-08-44-007C (Section 08 - Body and Accessories). .............................................................................................................................................................. .................................................................................. Dealers should not install a cloth or vinyl roof on vehicles that have been ordered with the XM radio option (RPO U2K) and/or OnStar(R) (RPO UE1). The performance of these systems may be negatively impacted by the installation of the cloth/vinyl roof. Additionally, water leaks may result from installing a cloth or vinyl roof on vehicles with roof-mounted antenna systems. Relocating the antenna to another spot on the vehicle exterior, in order to install a cloth or vinyl roof, is not advised either. The performance of the OnStar(R) and XM Radio antennas has been optimized for their current locations. Relocating the antennas may result in a performance degradation. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures Technical Service Bulletin # 09-08-46-001 Date: 090409 OnStar(R) - Generation 6 Service Procedures INFORMATION Bulletin No.: 09-08-46-001 Date: April 09, 2009 Subject: Servicing Vehicles Upgraded to OnStar(R) Generation 6 Digital‐Capable System (Follow Information Below) Models Attention: This bulletin is being issued to provide dealer personnel with information and the procedures to diagnose an upgraded OnStar(R) Generation 6 Digital-Capable system. Program Overview Since it was launched in 1996, OnStar® has relied on an analog wireless network to provide communication to and from OnStar-equipped vehicles. As part of an industry wide change in the North American wireless telecommunications industry, wireless carriers are transitioning to digital technology and will no longer support the analog wireless network beginning early 2008. Effective January 1, 2008, OnStar(R) service in the United States and Canada will be available only through vehicles that are capable of operating on the digital network. Refer to Corporate Bulletin Number 05-08-46-006H for information about upgrading certain vehicles to digital service. Details were covered in both the November 2006 and December 2007 issues of TechLink, which are available in the Archives of the TechLink website. Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within the OnStar(R) Canada Online Enrollment site that can be accessed from the OnStar(R) Brand Resources in GlobalConnect. Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9161 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9162 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9163 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9164 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9165 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9166 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9167 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9168 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9169 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9170 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9171 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9172 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9173 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9174 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9175 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9176 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9177 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9178 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9179 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9180 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9181 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9182 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9183 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9184 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9185 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9186 Circuit/System Testing Component Testing Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade Technical Service Bulletin # 05-08-46-006Q Date: 081028 OnStar(R) - Analog/Digital Ready System Digital Upgrade INFORMATION Bulletin No.: 05-08-46-006Q Date: October 28, 2008 Subject: Information on Upgrading Certain OnStar(R) Analog/Digital-Ready Systems to OnStar(R) Generation 6 Digital-Capable System Models Supercede: This bulletin is being revised to update the upgrade kit installation information for the 2001 Chevrolet Impala and Monte Carlo. Please discard Corporate Bulletin Number 05-08-46-006P (Section 08 - Body and Accessories). This bulletin is being issued to provide dealer personnel with information and procedures to follow should an owner wish to upgrade their OnStar(R) Analog/Digital-Ready system to an OnStar(R) Generation 6 Digital-Capable system. Disclaimer Program Overview Program Overview To upgrade their vehicle to an OnStar(R) Generation 6 Digital-Capable system, all that a customer must do is: ^ Take their vehicle to their dealer for the system upgrade. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9191 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9192 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9193 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9194 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9195 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9196 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9197 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9198 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9199 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9200 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9201 Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9202 Labor Time Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Analog/Digital System Information INFORMATION Bulletin No.: 06-08-46-008C Date: September 18, 2008 Subject: Information on OnStar(R) Dual-Mode (Analog/Digital) Systems Models Supercede: This bulletin is being revised to correct the model year range for the Chevrolet Impala and Monte Carlo and update the reference to GM Dealerworld. Please discard Corporate Bulletin Number 06-08-46-008B (Section 08 - Body and Accessories). All 2000-2003 model year vehicles equipped with OnStar® from the list above were built with Analog/Digital-Ready OnStar(R) Hardware. Some of these vehicles may have been upgraded to Dual-Mode (Analog/Digital). Certain 2004-2005 model year vehicles equipped with OnStar(R) from the list above may have been either: ^ Originally built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware with Dual-Mode (Analog/Digital) OnStar(R) Hardware OR ^ Upgraded to Dual-Mode (Analog/Digital) Hardware All 2006 model year and newer vehicles equipped with OnStar(R) were built at the factory with Dual-Mode (Analog/Digital) OnStar(R) Hardware. If a vehicle has Dual-Mode (Analog/Digital) OnStar(R) Hardware, then the system is capable of operating on both the analog and digital cellular Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 9207 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08-08-46-004 > Aug > 08 > OnStar(R) - Aftermarket Device Interference Information Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Aftermarket Device Interference Information INFORMATION Bulletin No.: 08-08-46-004 Date: August 14, 2008 Subject: Information on Aftermarket Device Interference with OnStar(R) Diagnostic Services Models: 2009 and Prior GM Passenger Car and Truck (including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X with OnStar(R) (RPO UE1) This bulletin is being issued to provide dealer service personnel with information regarding aftermarket devices connected to the Diagnostic Link Connector (DLC) and the impact to OnStar(R) diagnostic probes and Vehicle Diagnostic e-mails. Certain aftermarket devices, when connected to the Diagnostic Link Connector, such as, but not limited to, Scan Tools, Trip Computers, Fuel Economy Analyzers and Insurance Tracking Devices, interfere with OnStar's ability to perform a diagnostic probe when requested (via a blue button call) by a subscriber. These devices also prohibit the ability to gather diagnostic and tire pressure data for a subscriber's scheduled OnStar(R) Vehicle Diagnostic (OVD) e-mail. These aftermarket devices utilize the Vehicles serial data bus to perform data requests and/or information gathering. When these devices are requesting data, OnStar(R) is designed not to interfere with any data request being made by these devices as required by OBD II regulations. The OnStar(R) advisor is unable to definitively detect the presence of these devices and will only be able to inform the caller or requester of the unsuccessful or incomplete probe and may in some cases refer the subscriber/requester to take the vehicle to a dealer for diagnosis of the concern. When performing a diagnostic check for an unsuccessful or incomplete OnStar(R) diagnostic probe, or for concerns regarding completeness of the OnStar(R) Vehicle Diagnostic (OVD) e-mail, verify that an aftermarket device was not present at the time of the requested probe. Regarding the OVD e-mail, if an aftermarket device is interfering (including a Scan Tool of any type), the e-mail will consistently display a "yellow" indication in diagnostics section for all vehicle systems except the OnStar(R) System and Tire Pressure data (not available on all vehicles) will not be displayed (i.e. section is collapsed). Successful diagnostic probes and complete OVD e-mails will resume following the removal or disconnecting of the off-board device. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED Emergency Contact Module: All Technical Service Bulletins OnStar(R) - No Power/Inoperative/No LED TECHNICAL Bulletin No.: 05-08-46-001D Date: May 02, 2008 Subject: OnStar(R) Generation 5 or 6 (Digital) System Inoperative/Has No Power, LED Light Not On (Remove/Reinstall OnStar(R) Fuse and Replace VCIM or Follow SI Diagnostics) Models Supercede: This bulletin is being revised to update the information on VCIM ordering instructions in step 3 of the Correction statement. Please discard Corporate Bulletin Number 05-08-46-001C (Section 08 - Body & Accessories). Condition Some customers may comment any or all of the following conditions: ^ The OnStar(R) system may be inoperative. ^ The OnStar(R) system may have no power. ^ The OnStar(R) LED light may not be on. The technician may also not be able to communicate with the OnStar(R) Vehicle Communication Interface Module (VCIM) with a Tech 2(R). Correction Notice: On 2006 Chevrolet Impala and Monte Carlo models, make sure the ignition is OFF and the vehicle has "RAP"ed out prior to removing the OnStar(R) fuse. Disconnecting power to the OnStar(R) module while the ignition is ON may discharge and permanently damage the OnStar(R) back-up battery. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-001D > May > 08 > OnStar(R) - No Power/Inoperative/No LED > Page 9216 Important: This bulletin does NOT apply to 2006 vehicles built AFTER the VIN breakpoints listed above. Refer to applicable diagnostics in SI for those vehicles that exhibit this condition. Remove the OnStar(R) fuse from the fuse box, wait five minutes and reinstall the fuse. (For Saturn VUE vehicles, remove the "INT LTS" fuse from the I/P fuse block for five minutes, then reinstall the fuse.) If the OnStar(R) system DOES NOT return to normal functionality, then follow the diagnostics in SI for this condition. If the OnStar(R) system DOES return to normal functionality, perform the following steps: 1. Install the Tech 2(R) and determine what generation hardware and software ID is in the vehicle. 2. If the vehicle is equipped with Generation 5 hardware and a software version 146, the VCIM should have the B1000 reprogramming performed as described in Corporate Bulletin Number 04-08-46-004A. The system should be tested and if the concern returns, the VCIM should be replaced. 3. If Gen 5 with a software version OTHER than 146 or Gen 6 and above, the VCIM needs to be replaced and the system reconfigured. Refer to the current version of Corporate Bulletin 03-08-46-004 for details on how to order a new VCIM. Important: As with any OnStar(R) VCIM replacement, the OnStar(R) system must be reconfigured after replacement. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 00-08-46-004C > Jan > 08 > OnStar(R) - Re-establishing OnStar(R) Communications Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Re-establishing OnStar(R) Communications Bulletin No.: 00-08-46-004C Date: January 17, 2008 INFORMATION Subject: Re-establishing Communications with OnStar(R) Center After Battery Disconnect Models: 2000-2008 GM Passenger Cars and Trucks (Including Saturn and Saab) with Digital OnStar(R) (RPO UE1) Supercede: This bulletin is being revised to add models and model years. Please discard Corporate Bulletin Number 00-08-46-004B (Section 08 - Body and Accessories). When servicing any of the above models and a battery cable is disconnected or power to the OnStar(R) Vehicle Communication Interface Module (VCIM) is interrupted for any reason the following procedure must be performed to verify proper Global Positioning System (GPS) function. Never swap OnStar(R) Vehicle Communication Interface Modules (VCIM) from other vehicles. Transfer of OnStar(R) modules from other vehicles should not be done. Each OnStar(R) module has a unique identification number. The VCIM has a specific Station Identification (STID). This identification number is used by the National Cellular Telephone Network and OnStar(R) systems and is stored in General Motors Vehicle History files by VIN. After completing ALL repairs to the vehicle you must perform the following procedure: Move the vehicle into an open area of the service lot. Sit in the vehicle with the engine running and the radio turned on for five minutes. Press the OnStar(R) button in the vehicle. When the OnStar(R) advisor answers ask the advisor to verify the current location of the vehicle. If the vehicle location is different than the location the OnStar(R) advisor gives contact GM Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis of a failed VCIM and, if appropriate, order a replacement part. Replacement parts are usually shipped out within 24 hours, and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part, you will avoid a non-return core charge. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Incorrect GPS Position Reported During Call Bulletin No.: 02-08-46-006C Date: January 08, 2008 INFORMATION Subject: Incorrect OnStar(R) Global Positioning System (GPS) Location Reported During OnStar(R) Call Models: 2000-2008 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 02-08-46-006B (Section 08 - Body and Accessories). A small number of the above-mentioned vehicles may exhibit a condition in which the vehicle reports an inaccurate location to the OnStar(R) Call Center. This condition can only be identified via a button press to the OnStar(R) Call Center by the customer. Call Center personnel will be able to identify this inaccurate location condition. Customers will then be notified through the mail by OnStar(R) if their vehicle exhibits this condition. Once this condition has been identified OnStar(R) will instruct the customer to return to the dealership to have this condition corrected. It is not necessary to reconfigure the vehicle after the following procedure. In order to correct this condition you must cycle power to the OnStar(R) system. This can be done by either removing the fuses powering the OnStar(R) system or disconnecting the OnStar(R) module (VCIM) from the vehicle. As a last resort you can disconnect the vehicle's battery. The power needs to be removed from the system for approximately 15 minutes. After completing this procedure the vehicle should be taken to an area with an unobstructed view of the sky. The vehicle should be kept running for approximately 10 minutes to allow the vehicle to reacquire the global positioning system (GPS). Then contact the OnStar(R) Call Center via the blue OnStar(R) button and ask the advisor to verify the GPS position. If the OnStar(R) advisor still has an inaccurate GPS location refer to the Navigation Systems and Cellular Communications sub-sections in the Service Manual in order to diagnose and repair the concern. If the normal diagnostics lead to module replacement you will need to contact Technical Assistance (TAC) and choose the OnStar(R) prompt. GM OnStar(R) TAC will assist in the diagnosis and if appropriate order a replacement part. Replacement parts are usually shipped out within 24 hours and a pre-paid return package label will be included for returning the faulty part. By returning the faulty part you will avoid a significant non-return core charge. Warranty Information (excluding Saab US Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab US Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-006C > Jan > 08 > OnStar(R) - Incorrect GPS Position Reported During Call > Page 9225 For vehicles repaired under warranty use, the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues Emergency Contact Module: All Technical Service Bulletins OnStar(R) - Loss of GPS Signal/Hands Free Issues Bulletin No.: 02-08-46-007C Date: November 19, 2007 INFORMATION Subject: Information on OnStar(R) System - Possible Loss of GPS Signal, Hands-Free Calling Minutes Expire Prematurely and/or Inability to Add Hands-Free Calling Minutes Models: 2001-2008 GM Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2008 HUMMER H2 2006-2008 HUMMER H3 2005-2008 Saab 9-7X with OnStar(R) System (RPO UE1) Supercede: This bulletin is being revised to add the 2008 model year, warranty information and to provide GPS signal recovery steps (under Dealer Action heading) to do PRIOR to determining if the VIU/VCIM needs replacement. Please discard Corporate Bulletin Number 02-08-46-007B (Section 08 - Body & Accessories). If the vehicle currently has analog-upgradable OnStar(R) hardware, then the customer should be made aware of the digital upgrade program per the latest version of Service Bulletin # 05-08-46-006. Any analog OnStar system that is not upgraded prior to the end of 2007 will be deactivated due to the upcoming phase-out of the analog cellular network in the U.S. and Canada. If the vehicle has recently been upgraded or has had a service replacement unit installed, this bulletin may not be applicable. Certain 2001-2008 model year vehicles equipped with OnStar(R) may exhibit a condition with the Global Positioning System (GPS) that causes inaccuracies in the GPS clock. The GPS system is internal to the OnStar(R) Vehicle Interface Unit (VIU) or the Vehicle Communication Interface Module (VCIM). This inaccuracy can result in a symptom where the OnStar(R) Call Center is unable to obtain an accurate GPS signal, hands-Free Calling minutes expire prematurely and/or the inability to add Hands-Free calling minutes. Customer Notification OnStar(R) will notify the customer by mail with instructions to contact their dealership service department. Dealer Action Not all vehicles will require VIU/VCIM replacement. The GPS signal in some vehicles may be recoverable. To determine if the signal is recoverable, simply connect the Tech2(R) and using the GPS information data display option, observe the GPS date and time. If the date/time stamps are equal to a date approximately 19 years in the future, the GPS clock has exceeded its capacity and the VIU/VCIM will need to be replaced. If the date/time stamp is in the past or near future, the GPS clock has simply generated an inaccurate value and may be recoverable by performing the following power-up reset. To initiate a power-up reset, battery voltage (batt. +) must be removed from the VIU/VCIM. The preferred methods, in order, of initiating the reset are outlined below. Remove the fuse that supplies Battery positive (Batt. +) voltage to the module (refer to the applicable Service Information schematics for the appropriate fuse). The next preferred method is to remove the connector to the OnStar(R) unit that Batt + is contained. The least preferable method is to remove the negative terminal of the vehicle battery. This will not only initiate the power-up reset, but it may also result in the loss of radio presets and other stored personalization information/settings in other modules as well. After initiating the power-up reset, the GPS data will be set to the defaulted date and time and will require an acquisition of the GPS signal in order to gain the proper date and time. Acquiring the GPS signal requires running the vehicle in an open/unobstructed view of the sky. First, contact OnStar(R) Technical Support by pressing the blue button. Allow the OnStar(R) Technical Advisor to activate the GPS recovery process. This should take approximately 10 minutes. Continue to Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 9230 monitor the Tech2(R) for the current time and date. REMINDER - Keep in mind that the time displayed on the Tech2(R) is in Greenwich Mean Time (GMT) and the offset is based on the time zones relationship to GMT. If replacement of the VIU/VCIM is necessary, you MUST reconfigure the OnStar® system. Failure to reconfigure the system will result in an additional customer visit for repair. OnStar® VIU, Generations 2 and 3, will require the technician to press the blue OnStar® button to reconfigure the vehicle with an OnStar® advisor. OnStar(R) VCIM, Generations 4-7 will require the technician to reconfigure the vehicle with the use of the TIS2WEB and SPS applications (pass thru only), along with the Tech2(R). The configuration and set-up procedure is a two-step process that must be completed step-by-step without interruption or delay in between each step. This procedure enables an automated activation without a button press by the technician to the OnStar(R) Call Center. Following this procedure, it may take up to 24 hours for all OnStar(R) services to be fully activated. How to Order Parts If the OnStar(R) GPS date/time stamp is non-recoverable and the unit needs to be replaced, dealers in the U.S. should contact Autocraft Electronics select the catalog item that contains this bulletin number. Canadian dealers should contact MASS Electronics. Dealers DO NOT need to call the GM Technical Assistance Center (TAC) for replacement approval. Autocraft Electronics and MASS Electronics will be responsible for verifying that the subject vehicle is a candidate for a replacement VIU/VCIM. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use the table. Warranty Information (Saab U.S. Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 02-08-46-007C > Nov > 07 > OnStar(R) - Loss of GPS Signal/Hands Free Issues > Page 9231 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9241 If you are unsure who the PSC is, check with the Sales Manager. General Information 1. The first step is to verify if the OnStar(R) account is active or not. This can be done by pressing the blue OnStar(R) button and connecting to the OnStar(R) call center. Analog only accounts are no longer active. Only digital upgraded accounts will be active. On Gen 6 digital systems, a clear, or "dark" LED may indicate that the OnStar(R) system has been deactivated or may possibly have a no power/no communication condition. 2. If the account isn't active, the next step is to verify what version of OnStar(R) module is in the vehicle. This can be done via the Tech 2 (Body>VCIM>Module ID Information>Module Information 2) or by using www.onstarenrollment.com. 3. A Generation 5 or older analog module can be diagnosed by following the original electronic Service Information developed for the model year of the vehicle. Note: If the customer has an old analog module, the vehicle can be repaired by replacing the module, but the customer cannot have an active account without upgrading to a digital module. 4. Modules, antennas, brackets, and other equipment are in the same location, whether original analog production or digital upgrade. 5. An upgraded vehicle may also have a new vehicle communication interface module (VCIM) bracket. If it does, order the new bracket when replacing the bracket. Don't order the original bracket. The kit may also include a small wiring jumper cable. If it does, this jumper will be required for a new module replacement. Do not discard. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9242 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9243 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9244 Vehicles Built with Upgradeable OnStar(R) System Analog Modules Note: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9245 2007 Model Year Vehicles and Newer all have Digital OnStar(R) Modules. Part 1 OnStar(R) Description and Operation This OnStar(R) digital system consists of the following components: ^ Vehicle Communication Interface Module (VCIM) ^ OnStar(R) button assembly ^ Microphone ^ Cellular antenna ^ Navigation antenna Note This system also interfaces with the factory installed vehicle audio system. Vehicle Communication Interface Module (VCIM) The vehicle communication interface module (VCIM) is a cellular device that allows the user to communicate data and voice signals over the national cellular network. Power is provided by a dedicated, fused B+ circuit. Ground is provided through the vehicle wiring harness attached to the module. The ignition state is determined by the VCIM through serial data messaging. Dedicated circuits are used to connect the VCIM to a microphone, the button assembly, and to command the status LED. The VCIM communicates with the rest of the vehicle modules using the serial data bus. The module houses 2 technology systems, one to process GPS data, and another for cellular information. The cellular system connects the OnStar(R) system to the cellular carrier's communication system by interacting with the national cellular infrastructure. The module sends and receives all cellular communications over the cellular antenna and cellular antenna coax. GPS satellites orbiting earth are constantly transmitting signals of their current location. The OnStar(R) system uses the GPS signals to provide location on demand. The module also has the capability of activating the horn, initiating door lock/unlock, or activating the exterior lamps using the serial data circuits. These functions can be commanded by the OnStar(R) Call Center per: a customer request. OnStar(R) Button Assembly The OnStar(R) button assembly may be part of the rearview mirror, or a separate, stand alone unit. The button assembly is comprised of 3 buttons and a status LED. The buttons are defined as follows: ^ The answer/end call button, which is black with a white phone icon, allows the user to answer and end calls or initiate speech recognition. ^ The blue OnStar(R) call center button, which displays the OnStar(R) logo, allows the user to connect to the OnStar(R) call center. ^ The emergency button, which displays a white cross with a red background, sends a high priority emergency call to the OnStar(R) call center when pressed. The VCIM supplies 10 volts to the OnStar(R) button assembly on the keypad supply voltage circuit. When pressed, each button completes a circuit across a resistor allowing a specific voltage to be returned to the VCIM on the keypad signal circuit. Depending upon the voltage range returned the VCIM is able to identify which button has been pressed. The OnStar(R) status LED is located with the button assembly. The LED is green when the system is ON and operating normally. When the status LED is green and flashing, it is an indication that a call is in progress. When the LED is red, this indicates a system malfunction is present. In the event there is a system malfunction and the OnStar(R) system is still able to make a call, the LED will flash red during the call. If the LED does not illuminate, this may indicate that the customers OnStar(R) subscription is not active or has expired. Push the blue OnStar button to connect to an advisor who can then verify the account status. Each LED is controlled by the VCIM over dedicated LED signal circuits. Ground for the LED is provided by the wiring harness attached to the button assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9246 OnStar(R) Microphone The OnStar(R), or cellular microphone, can be a part of the rearview mirror assembly, or on some vehicle lines, a separate, stand alone unit. In either case, the VCIM supplies approximately 10 volts to the microphone on the cellular microphone signal circuit, and voice data from the user is sent back to the VCIM over the same circuit. A cellular microphone low reference circuit or a drain wire provides a ground for the microphone. Cellular and GPS Antennas The vehicle will be equipped with one of the following types of antennas: ^ Separate, stand-alone cellular and navigation (GPS) antennas. ^ A combination cellular and navigation (GPS) antenna, which brings the functions of both into a single part. ^ A cellular, GPS, and digital radio receiver (DRR) antenna, which also incorporates the functionality of the DRR satellite antenna (XM). The cellular antenna is the component that allows the OnStar(R) system to send and receive data using electromagnetic waves by means of cellular technology. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The GPS antenna is used to collect the signals of the orbiting GPS satellites. Within the antenna is housed a low noise amplifier that allows for a more broad and precise reception of this data. The antenna is connected at the base to a coax cable that plugs directly into the VCIM. The cable also provides a path for DC current for powering the antenna. The OnStar(R) Call Center also has the capability of communicating with the vehicle during an OnStar(R) call to retrieve the latest GPS location and transmit it to the OnStar(R) Call Center. A history location of the last recorded position of the vehicle is stored in the module and marked as aged, for as long as the module power is not removed. Actual GPS location may take up to 10 minutes to register in the event of a loss of power. Audio System Interface When the OnStar(R) requires audio output, a serial data message is sent to the audio system to mute all radio functions and transmit OnStar(R) originated audio. The OnStar(R) audio is transmitted to the vehicle audio system by a dedicated signal circuit and a low reference circuit. The audio system will mute and an audible ring will be heard though the speakers if the vehicle receives a call with the radio ON. On some vehicles, the HVAC blower speed may be reduced when the OnStar(R) system is active to aid in reducing interior noise. When the system is no longer active, the blower speed will return to its previous setting. OnStar(R) Steering Wheel Controls Some vehicles may have a button on the steering wheel, that when pushed can engage the OnStar(R) system. The button may be a symbol of a face with sound waves, or may say MUTE, or be a symbol of a radio speaker with a slash through it. By engaging the OnStar(R) system with this feature, the user can interact with the system by use of voice commands. A complete list of these commands is supplied in the information provided to the customer. If the information is not available for reference, at any command prompt, the user can say "HELP" and the VCIM will return an audible list of available commands. The steering wheel controls consist of multiple momentary contact switches and a resistor network. The switches and resistor network are arranged so that each switch has a different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network. This produces a specific voltage value unique to the switch selected, to be interpreted by the radio or the body control module (BCM). OnStar(R) Power Moding (DRX or Sleep Cycle) The OnStar(R) system uses a unique sleep cycle to allow the system to receive cellular calls while the ignition is in the OFF position and retained accessory power (RAP) mode has ended. A green status LED on the OnStar(R) keypad normally indicates an active OnStar(R) account. The OnStar(R) system will stay powered up after ignition off for an extended time in order to allow for remote services like door unlock, horn honk, light flash, etcetera to take place as requested by the customer. Power cycle (also referred to as DRX) times vary depending on the generation of the OnStar(R) system. Technicians may identify the OnStar(R) system generation by using a Tech 2 and following this menu path: (Body>VCIM>Module ID Information>Module Information 2) or by accessing www.onstarenrollment.com All Generation 6 digital systems are powered up continuously for 48 hours from ignition OFF. After 48 hours, the Generation 6 systems will enter a 9 minute OFF, 1 minute ON power cycle for an additional 72 hours. At the beginning and end of the 1 minute ON stage, you may or may not experience a short spike of current at the beginning and at the end. This allows for calls from OnStar to be received by the system. After 120 hours from ignition OFF, Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9247 these systems will then completely power OFF. OnStar(R) Module Expected Current Draw The expected current draw of the OnStar(R) module in various ignition modes are as follows: ^ Ignition ON ‐ 240 to 400 mA ^ Ignition OFF ‐ 3 to 20 mA for 48 hours ^ Ignition OFF ‐ 0.2 to 0.8 mA after 48 hours (120 hours on specified vehicle communication platforms (VCPs)). Note During extended voltage testing for battery parasitic draw, it is possible to observe a voltage spike caused by the following: ^ A cellular registration call that was triggered by the local cellular system. ^ The OnStar(R) system has set a monthly trigger for a vehicle data upload call for the OnStar(R) Vehicle Diagnostic E‐mail upload. OnStar(R) System States of Readiness The OnStar(R) system will use the following 4 states of readiness, depending upon the type of cellular market the vehicle is in when the ignition is turned OFF. ^ High power ^ Low power ^ Sleep ^ Digital standby The high power state is in effect whenever the ignition is in the ON or RUN position, retained accessory power (RAP) is enabled, and/or the OnStar(R) system is sending or receiving calls or when the system is performing a remote function. The low power state is in effect when the OnStar(R) system is idle with the ignition in the ON or RUN position, or with RAP enabled. The sleep state is entered after the vehicle has been shut OFF and the RAP has timed out. At a predetermined time recorded within the VCIM, the system re-enters the low power state to listen for a call from the OnStar(R) Call Center for 1 minute. After this interval, the system will again return to the sleep state for 9 minutes. If a call is sent during the 1 minute interval, the OnStar(R) system will receive the call and immediately go into the high power mode to perform any requested functions. If a call is not received during the 1 minute interval, the system will go back into the sleep mode for another 9 minutes. This process will continue for up to 48 hours, after which the OnStar(R) system will turn OFF until the ignition is turned to the ON or RUN position. The digital standby power state is entered after the vehicle has been shut off and the RAP has timed out while in a digital cellular area. When in digital standby mode, the OnStar(R) module is able to perform all remote functions as commanded by an OnStar(R) advisor at any time, for a continuous 48 hours. After 48 hours, the OnStar(R) module will go into sleep mode until a wake up signal from the vehicle is seen by the CIM. If the OnStar module loses the digital cellular signal it will revert to analog mode and follow the standard sleep state (9 minutes OFF, 1 minute standby) based on the time of the GPS signals, this will continue until a digital cellular signal is again received. If the OnStar(R) system loses battery power while the system is in a standby or sleep mode, the system will remain OFF until battery power is restored and the ignition is turned to the ON or RUN position. Deactivated OnStar(R) Accounts In the event that a customer has not upgraded their vehicle to a digital system, the account has been deactivated. The customers have been previously notified of the steps required to upgrade their vehicles. After the OnStar(R) account has been deactivated, customers will experience the following: ^ The OnStar(R) status LED will not illuminate ^ The OnStar(R) system will NOT attempt to connect to the OnStar(R) Call Center in the event of a collision or if the vehicle's front air bags deploy for any other reason. ^ An emergency button press will result in a demo message being played, indicating the service has been deactivated and needs to be upgraded. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9248 ^ An OnStar(R) Call Center button press WILL NOT connect the vehicle with OnStar(R). The vehicle must be upgraded to reactivate the account. The customer will hear a demo message stating that there is not a current OnStar(R) subscription for the vehicle. The message will also instruct the customer how to upgrade and reactivate services. ^ OnStar(R) personal calling (OPC) will not be available, as this feature requires the customer to have a current OnStar(R) account. Attempts to use this feature will result in cellular connection failure messages and the inability to connect to the number dialed. Note For deactivated vehicles, a no connect response should be considered normal system operation. Further diagnosis and subsequent repair is only necessary should the customer elect to become an active OnStar(R) subscriber and upgrade the account subscription. OnStar(R) Cellular, GPS, and Diagnostic Limitations The proper operation of the OnStar(R) System is dependent on several elements outside the components integrated into the vehicle. These include the National Cellular Network Infrastructure, the cellular telephone carriers within the network, and the GPS. The cellular operation of the OnStar(R) system may be inhibited by factors such as the users range from a digital cellular tower, the state of the cellular carrier's equipment, and the location where the call is placed. Making an OnStar(R) key press in areas that lack sufficient cellular coverage or have a temporary equipment failure will result in either the inability of a call to complete with a data transfer or the complete inability to connect to the OnStar(R) Call Center. The OnStar(R) system may also experience connection issues if the identification numbers for the module, station identification number (STID), electronic serial number (ESN) or manufacturers electronic ID (MEID), are not recognized by the cellular carriers local signal receiving towers. The satellites that orbit earth providing the OnStar system with GPS data have almost no failures associated with them. In the event of a no GPS concern, the failure will likely lie with the inability of the system to gain GPS signals because of its location, i.e. in a parking structure, hardware failure, or being mistaken with an OnStar(R) call which has reached the Call Center without vehicle data. During diagnostic testing of the OnStar(R) system, the technician should ensure the vehicle is located in an area that has a clear unobstructed view of the open sky, and preferably, an area where digital cellular calls have been successfully placed. These areas can be found by successfully making an OnStar(R) keypress in a known good OnStar(R) equipped vehicle and confirming success with the OnStar(R) Call Center advisor. Such places can be used as a permanent reference for future OnStar(R) testing. Mobile Identification Number and Mobile Directory Number The vehicle communication interface module (VCIM) utilizes 2 numbers for cellular device identification, call routing and connection. They are: ^ A mobile identification number (MIN) ^ A mobile directory number (MDN) Note The MIN represents the number used by the cellular carrier for call routing purposes. The MDN represents the number dialed to reach the cellular device. Diagnostic Information Symptoms - Cellular Communication The following steps must be completed before using the symptom table. 1. Perform the Diagnostic System Check - Vehicle, before using the Symptom Tables in order to verify that the following are true: ^ There are no DTCs set. ^ The control modules can communicate via the serial data link. 2. Review the system operation in order to familiarize yourself with the system functions. Refer to Radio/Audio System Description and Operation in SI. Diagnostic Starting Point - Displays and Gages Begin the displays and gages system diagnosis with Diagnostic System Check - Vehicle or the audible warning system diagnosis with Diagnostic System Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9249 Check - Vehicle. The Diagnostic System Check will provide the following information: ^ The identification of the control modules which command the system ^ The ability of the control modules to communicate through the serial data circuit ^ The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Visual/Physical Inspection Perform the following visual inspections; ^ Inspect for aftermarket devices which could affect the operation of the Radio/Audio System. Refer to Checking Aftermarket Accessories in SI. ^ Inspect the easily accessible and visible system components for obvious damage or conditions which could cause the symptom. Intermittent Conditions Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for Intermittent Conditions and Poor Connections in SI. Symptom List Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9250 Diagnostic Trouble Codes DTC U1000 and U1255 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. When a module does not associate an identification number with at least one critical parameter within 5 seconds of beginning serial data communication, DTC U1000 or U1255 DTC is set. When more than one critical parameter does not have an identification number associated with it, the DTC will only be reported once. The Class 2 serial data communications circuit on this vehicle are in a hybrid ring and star configuration. Each module on the ring has 2 serial data circuits connected to it, except the following modules which have only 1 serial data circuit connected them: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9251 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Front passenger door module (FPDM) ^ Left rear door module (LRDM) ^ Memory seat module (MSM) ^ Radio antenna module (listed as remote function actuation in scan tool display) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ TV antenna module ^ Vehicle communication interface module (VCIM) The star has 4 splice packs: ^ SP200 located in the left side of the instrument panel, near the steering column , taped to the instrument panel harness ^ SP201 located in the center of the instrument panel, near the radio ^ SP300 located in the left side middle of the passenger compartment, taped to the body harness, near the carpet seam ^ SP303 located in the right rear of the passenger compartment, taped to the body harness, approximately 24 cm (9.5 in) from the fuse block - right rear. Refer to Data Communication Schematics in SI. The following modules, components, and splice packs are connected to the ring portion of the class 2 serial data circuit: ^ Dash integration module (DIM) ^ Electronic brake control module (EBCM) ^ Engine control module (ECM) ^ Inflatable restraint sensing and diagnostic module (SDM) ^ Instrument panel cluster (IPC) ^ HVAC control module ^ Radio ^ Rear integration module (RIM) ^ Vehicle communication interface module (VCIM) OR ^ Communication interface module (CIM) ^ SP200 ^ SP201 ^ SP300 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9252 ^ SP303 The following modules, components, and splice pack are connected to the star portion of the class 2 serial data circuit: ^ SP300 ^ Audio amplifier ^ Driver door module (DDM) ^ Driver door switch assembly (DDSA) ^ Memory seat module (MSM) ^ Left rear door module (LRDM) AND ^ SP303 ^ Antenna module ^ Front passenger door module (FPDM) ^ Rear integration module (RIM) ^ Right rear door module (RRDM) ^ Theft deterrent module (TDM) ^ Vehicle communication interface module (VCIM). Refer to Data Communication Schematics and Data Link Communications Description and Operation in SI. Part 2 Conditions for Running the DTC Voltage supplied to the module is in the normal operating voltage range of 9 - 16 volts. DTCs B1327, B1328, U1300, U1301, U1305 are not set as current. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A message containing a critical operating parameter has not been received within the last 5 seconds after establishing class 2 serial data communication. Action Taken When the DTC Sets The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When a malfunction such as an open fuse to a module occurs while modules are communicating, a DTC U1001-1254 Loss of XXX Communications is set current. When the modules stop communicating the current DTC U1001-1254 Loss of XXX Communications is cleared but the history DTC remains. When the modules begin to communicate again, the module with the open fuse will not be learned by the other modules so U1000 or U1255 is set current by the other modules. If the malfunction occurs when the modules are not communicating, only U1000 or U1255 is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9253 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9254 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9255 Test Description DTC U1001 and U1254 Circuit/System Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. When a module receives a message for a critical operating parameter, the module records the identification number of the module which sent the message for State of Health monitoring. A critical operating parameter is one which, when not received, requires that the module use a default value for that parameter. Once an identification number is learned by a module, it will monitor for that module's Node Alive message. Each module on the class 2 serial data circuit which is powered and performing functions that require detection of a communications malfunction is required to send a Node Alive message every 2 seconds. When no message is detected from a learned identification number for 5 seconds, a DTC U1XXX where XXX is equal to the 3-digit identification number is set. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9256 The control module ID number list above provides a method for determining which module is not communicating. A module with a class 2 serial data circuit malfunction or which loses power during the current ignition cycle will have a Loss of Communication DTC set by other modules that depend on information from that failed module. The modules that can communicate will set a DTC indicating the module that cannot communicate. Diagnostic Order When more than one Loss of Communication DTC is set in either one module or in several modules, diagnose the DTCs in the following order: 1. Current DTCs before history DTCs unless told otherwise in the diagnostic table. 2. The DTC which is reported the most times. 3. From the lowest number DTC to the highest number DTC. Conditions for Running the DTC The following DTCs do not have a current status: ^ B1327 ^ B1328 ^ U1300 ^ U1301 ^ U1305 AND ^ The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTC A node alive message has not been received from a module with a learned identification number within the last 5 seconds. Action Taken When the DTC Sets Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9257 The module uses a default value for the missing parameter. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold, without a repeat of the malfunction. Diagnostic Aids When multiple Loss of Communication DTCs are set concurrently, the cause is likely to be 2 opens in the ring portion of the class 2 serial data circuit. Use the Control Modules and Devices ‐ Description and Identification Number table in order to determine which modules are not communicating. Use the class 2 serial data circuit schematic in order to determine the location of the opens. Test Description Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9258 The number above refers to the step number on the diagnostic table. DTC U0073 or U2100 DTC Descriptors DTC U0073 00: Control Module Communication Bus Off DTC U0073 71: ECU HS Bus Off DTC U0073 72: ECU LS Bus Off DTC U2100 00: Controller Area Network (CAN) Bus Communication DTC U2100 47: Controller Area Network (CAN) Bus Communication Circuit/System Description The serial data circuits are serial data buses used to communicate information between the control modules. The serial data circuits also connect directly to the data link connector (DLC). Conditions for Running the DTCs Supply voltage at the modules are in the normal operating range. The vehicle power mode requires serial data communications. Conditions for Setting the DTC The module setting the DTC has attempted to establish communications on the serial data circuits more than 3 times. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9259 Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. This DTC cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U0140 - U0184 Circuit Description Modules connected to the GMLAN serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. When the module detects one of the following conditions on the GMLAN serial data circuit, a DTC will set. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the GMLAN serial data circuit. Conditions for Setting the DTCs Diagnostic algorithms are designed so that a single point failure within a particular node shall result in a single DTC/FTB combination being set. Any recognized faults shall generate one DTC. Recognized faults may include but are not limited to the following: ^ Open or shorted condition on an I/O Circuit outside of normal operation of that circuit. ^ Erratic signal of a circuit, outside of normal operation, which can be readily and repeatedly recognized as erratic. ^ A condition, outside of normal operation, which causes a customer perception of a performance problem. ^ A condition whether hardware or data link error, which causes a device to operate in a default or fail soft mode. ^ A condition which changes or limits system performance. ^ Network supervision/signal supervision errors. ^ ECU Internal errors. ^ Criteria determined by legislation. An initialization or shutdown self-test shall be performed and may include but is not limited to the following: ^ RAM check ^ ROM/EEPROM/Flash check Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9260 ^ I/O check Any faults detected during the initialization self-test shall generate a DTC. All nodes also continuously perform a self-test while in an active state. DTCs and their associated telltales will set as a result of unprogrammed or unlearned information. DTCs, which are defined for system configuration (e.g. Vehicle Option Content not programmed) do not support the history status bit (set =0). Warning indicator bit is also set, when applicable, while this DTC is present. Action Taken When the DTCs Sets The module suspends all message transmission. The module uses default values for all parameters received on the serial data circuits. The module inhibits the setting of all other communication DTCs. Conditions for Clearing the DTC A current DTC clears when the malfunction is no longer present. A history DTC clears when the module ignition cycle counter reaches the reset threshold of 50, without a repeat of the malfunction. Circuit/System Verification Refer to Data Link References to determine which serial data system is used for a specific module. The DTCs cannot be retrieved with a current status. Diagnosis is accomplished using the following symptom procedures: Scan Tool Does Not Communicate with High Speed GMLAN Device in SI. OR Scan Tool Does Not Communicate with Low Speed GMLAN Device in SI. DTC U1300, U1301, or U1305 Circuit Description Modules connected to the Class 2 serial data circuit monitor for serial data communications during normal vehicle operation. Operating information and commands are exchanged among the modules. In addition to this, Node Alive messages are transmitted by each module on the Class 2 serial data circuit about once every 2 seconds. When the module detects one of the following conditions on the Class 2 serial data circuit for approximately 3 seconds, the setting of all other Class 2 serial communication DTCs is inhibited and a DTC will set. Conditions for Running the DTCs Voltage supplied to the module is in the normal operating voltage range. The vehicle power mode requires serial data communication to occur. Conditions for Setting the DTCs No valid messages are detected on the Class 2 serial data circuit. The voltage level detected on the Class 2 serial data circuit is in one of the following conditions: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9261 High OR Low The above conditions are met for more than 3 seconds. Circuit/System Verification These DTCs cannot be retrieved with a current status. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. An intermittent condition is likely to be caused by a short on the Class 2 serial data circuit. To diagnose use the Scan Tool Does Not Communicate with a Class 2 Device. Refer to SI. DTC B2455 DTC Descriptors DTC B2455 01: Cellular Phone Microphone Circuit Short to Battery DTC B2455 02: Cellular Phone Microphone Circuit Short to Ground DTC B2455 04: Cellular Phone Microphone Circuit Open Circuit Circuit/System Description Without RPO UAV The vehicle communication interface module (VCIM) uses the cellular phone microphone to allow driver communication with OnStar(R). With RPO UAV The vehicle communication interface module (VCIM) and navigation radio use the cellular phone microphone to allow driver communication with OnStar(R), as well as to operate the voice recognition/voice guidance feature of the navigation radio. Conditions for Running the DTC The ignition is in RUN or ACC position. System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 10 seconds. Conditions for Setting the DTC B2455 01: A short to battery is detected on the cellular microphone signal circuit. B2455 02: A short to ground is detected on the cellular microphone signal circuit. B2455 04: An open circuit is detected on the cellular microphone signal circuit. Action Taken When the DTC Sets The VCIM and/or navigation radio (RPO UAV) will not receive any signal from the microphone. The OnStar(R) status LED turns red. Voice recognition will not function. Conditions for Clearing the DTC Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9262 A current DTC clears when the condition for setting the DTC is no longer present. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Without RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 5. If all circuits test normal, test or replace the cellular microphone. Circuit/System Testing With RPO UAV 1. Turn OFF the ignition and all electrical components, including the scan tool. 2. Disconnect the X4 harness connector at the navigation radio and the harness connector at the cellular microphone. 3. Test for less than 5 Ohms between the low reference circuit terminal A and ground. ^ If greater than the specified range, test the low reference circuit for an open/high resistance. If the circuit tests normal, replace the VCIM. Refer to the appropriate vehicle in SI. 4. Ignition ON, test for 9 - 11 volts between the signal circuit terminal B and ground. ^ If greater than the specified range, test the signal circuit for a short to voltage. If the circuit tests normal, replace the VCIM. ^ If less than the specified range, test the signal circuit for a short to ground or an open/high resistance. If the circuit tests normal, replace the VCIM. 5. If all circuits test normal, test or replace the cellular microphone. 6. Connect the X4 harness connector at the navigation radio. 7. With a scan tool, verify that DTC B2455 is not set as current in the navigation radio. ^ If DTC B2455 is set as current, replace the navigation radio. Refer to the appropriate vehicle in SI. DTC B2462, B2483, or B2484 Circuit/System Description The vehicle communication interface module (VCIM) receives information from a specific navigation antenna located on the outside of the vehicle. The navigation antenna is connected to the VCIM via a shielded coaxial cable. The antenna cable also provides a path for DC current for powering the antenna. DTC Descriptors DTC B2462 02: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2462 04: Global Positioning System (GPS) Antenna Malfunction Open Circuit Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9263 DTC B2483: Global Positioning System (GPS) Antenna Malfunction Short to Ground DTC B2484: Global Positioning System (GPS) Antenna Malfunction Open Circuit Conditions for Running the DTCs The ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTCs B2462 02: The CIM detects a short to ground on the navigation antenna signal circuit. B2462 04: The CIM detects an open/high resistance on the navigation antenna signal circuit. B2483: The CIM detects a short to ground on the navigation antenna signal circuit. B2484: The CIM detects an open/high resistance on the navigation antenna signal circuit. Action Taken When the DTCs Set The OnStar(R) status LED turns red. The OnStar(R) Call Center cannot locate the vehicle. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 50 consecutive malfunction-free ignition cycles have occurred. Circuit/System Testing Turn OFF the ignition. 1. Disconnect the navigation antenna coax cable from the VCIM. 2. Ignition ON, test for 4.5-5.5 volts between the VCIM coax cable center conductor terminal at the VCIM and ground. ^ If not within the specified range, replace the VCIM. Refer to the appropriate vehicle in SI. 3. Reconnect the coax cable to the VCIM. 4. Disconnect the coax cable from the navigation antenna. 5. Test for 4.55.5 volts between the coax cable center conductor and the outer shield. ^ If not within the specified range, replace the coax cable. 6. If all circuits test normal, replace the navigation antenna. Refer to the appropriate vehicle in SI. DTC B2470 DTC Descriptor DTC B2470 04: Cellular Phone Antenna Circuit Malfunction Open Circuit Circuit/System Description The cellular antenna is connected to the vehicle communication interface module (VCIM) with an RG-58 coax cable. The VCIM collects the data from the cellular antenna once every second. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9264 Conditions for Running the DTC Ignition is in RUN or ACC position System voltage is between 9.5 - 15.5 volts. The above conditions are met for more than 1 second. Conditions for Setting the DTC The VCIM does not detect the presence of a cellular antenna for more than 1 second. Action Taken When the DTC Sets The vehicle is unable to connect to the OnStar(R) Call Center. The OnStar(R) status LED turns red. Conditions for Clearing the DTC The VCIM detects the presence of a cellular antenna. A history DTC clears after 50 malfunction-free ignition cycles. Circuit/System Testing Perform a visual inspection as shown above in order to verify that the cellular antenna and the cellular antenna coupling assembly are not damaged. If any components are damaged replace the assembly. DTC B2476 or B2482 DTC Descriptors Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9265 DTC B2476 04: Cellular Phone Select Service Switch Open Circuit DTC B2476 59: Cellular Phone Select Service Switch Stuck Button DTC B2482 00: Cellular Phone Select Service Switch Range/Performance Circuit Short to Ground Open / High Resistance Short to Voltage Signal Performance Circuit/System Description The OnStar(R) button assembly consists of 3 buttons, Call/Answer, OnStar(R) Call Center, and OnStar(R) Emergency. The vehicle communication interface module (VCIM) supplies the OnStar(R) button assembly with 10 volts via the keypad supply voltage circuit. Each of the buttons, when pressed, completes the circuit across a resistor allowing a specific voltage to be returned to the VCIM over the keypad signal circuit. Depending upon the voltage range returned, the VCIM is able to identify which button has been activated. Conditions for Running the DTCs The ignition is ON. System voltage is between 9 - 16 volts. Conditions for Setting the DTCs B2476 04: The VCIM detects an open/high resistance on the keypad supply voltage circuit. B2482 and B2476 59: The VCIM detects a valid signal on the keypad signal circuit for more than 15 seconds. If one of the OnStar(R) buttons is held or stuck for 15 seconds or more, the VCIM will set these DTCs. Action Taken When the DTCs Set The OnStar(R) status LED turns red. No calls can be placed. The VCIM will ignore all inputs from the OnStar® button assembly. Conditions for Clearing the DTCs The condition responsible for setting the DTC no longer exists. A history DTC will clear once 100 consecutive malfunction-free ignition cycles have occurred. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 09-08-46-001 > Apr > 09 > OnStar(R) - Generation 6 Service Procedures > Page 9266 Circuit/System Testing Component Testing Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) Technical Service Bulletin # 08089C Date: 081118 Campaign - Deactivation Of Analog OnStar(R) # 08089C: Special Coverage Adjustment - Analog OnStar Deactivation (Nov 18, 2008) Subject: 08089C -- SPECIAL COVERAGE ADJUSTMENT - ANALOG ONSTAR(R) DEACTIVATION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9271 Models The service procedure in this bulletin has been revised. Step 11 in the procedure for the 2004-2005 Saab 9-3 (9440) Convertible has been revised. Discard all copies of bulletin 08089B, issued September 2008. Condition In November 2002, the U.S. Federal Commissions (FCC) ruled that wireless carriers would no longer be required to support the analog wireless network beginning in 2008. As a result, On Star(R) is unable to continue analog service. OnStar(R) has deactivated most of the systems operating in the analog mode; however, there are some vehicles that OnStar(R) could not deactivate. Although the analog OnStar(R) hardware in these vehicles can no longer communicate with OnStar(R), the hardware in the vehicle is still active. If the OnStar(R) emergency button is pressed, or in the case of an airbag deployment, or near deployment, the customer may hear a recording that OnStar(R) is being contacted. However, since analog service is no longer available, the call will not connect to OnStar(R). To end the call, the customer must press the white phone or white dot button. If the call is not ended, the system will continue to try to connect to OnStar(R) until the vehicle battery is drained. Special Policy Adjustment At the customer's request, dealers/retailers are to deactivate the OnStar(R) system. The service will be made at no charge to the customer. This special coverage covers the condition described above until December 31, 2008 for all non-Saab vehicles; April 30, 2009 for all Saab vehicles. Vehicles Involved Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9272 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9273 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9274 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9275 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9276 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9277 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9278 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9279 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9280 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9281 Involved are certain vehicles within the VIN breakpoints shown above. PARTS INFORMATION -- Saab US Only Customer Notification General Motors will notify customers of this special coverage on their vehicles (see copy of typical customer letter shown in this bulletin - actual divisional letter may vary slightly). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9282 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9283 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9284 Claim Information - GM, Saturn Canada and Saab Canada Only Claim Information - Saturn US Only Customer Reimbursement Claims - Special Attention Required Customer reimbursement claims must have entered into the "technician comments" field the CSO # (if repair was completed at a Saturn Retail Facility) date, mileage, customer name, and any deductibles and taxes paid by the customer. Claim Information - Saab US Only Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9285 1. To receive credit, submit a claim with the information above. Disclaimer 2001 and Older Model Year Vehicles (Except Saab Vehicles) 2001 and Older Model Year Vehicles (Except Saab Vehicles) Important: 2001 and older model year vehicles require the removal of the battery power from the OnStar(R) vehicle interface unit (VIU) to eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. 1. Locate and gain access to the OnStar® VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. Important: Complete removal of the VIU is usually not required. Perform only the steps required to gain access to the C2 32-way blue connector. Residing in the C2 connector are the battery positive (+) circuits. Removal of the C2 connector will deactivate the unit and eliminate the possibility of an inadvertent OnStar(R) or emergency/airbag call. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9286 2. Disconnect the C2 32-way blue connector from the VIU and tape the connector to a secure location. Refer to Cellular Communications Connector End Views and related schematics in SI, if required. Important: DO NOT perform the OnStar(R) reconfiguration and/or programming procedure. 3. Secure the VIU in its original brackets and/or mounting locations and reinstall the VIU and interior components that were removed to gain access to the VIU. Refer to OnStar Vehicle Interface Unit Replacement in SI. 2002 Through 2006 Model Year Vehicles (Except Saab Vehicles) 2002 through 2006 Model Year Vehicles (Except Saab Vehicles) Important: The Tech 2 diagnostic tool must be updated with version 28.002 or later in order to successfully perform the VCIM setup procedure and disable the analog system. 1. Connect the Tech 2 to the data link connector (DLC), which is located under the instrument panel of the vehicle. 2. Turn the Tech 2 ON by pressing the power button. Important: Tech 2 screen navigation to get to the setup procedure depends on the year and make of the vehicle. The actual name of the setup procedure (Setup New OnStar or VCIM Setup) depends on model year and vehicle make as well. Example Tech 2 navigation to the setup procedure Tech 2 screen is provided below. ^ Diagnostics >> (2) 2002 >> Passenger Car >> Body >> C >> OnStar >> Special Functions >> Setup New OnStar >> ^ Diagnostics >> (5) 2005 >> Passenger Car >> (4) Buick >> C >> Body >> Vehicle Comm. Interface Module >> Module Setup >> VCIM Setup >> 3. Setup VCIM using the Tech 2. Follow on-screen instructions when you have reached the setup Tech 2 screen. 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 2000-2002 Saab 9-3 (9400) 4D/5D; 2000-2003 Saab 9-3 (9400) CV 1. Remove the ground cable from the battery's negative terminal. 2. Apply the handbrake brake. 3. Detach the floor console. 4. Remove the switch and the floor console: 3.1. Twist loose the immobilizer unit (A), bayonet fitting. Unplug the unit's connector. 3.2. Remove the ignition switch cover (B) by first undoing the rear edge of the cover and then unhooking the front edge. Unplug the ignition Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9287 switch lighting connector. 3.3. Undo the floor console's retaining bolts (C). 3.4. Take out the rear ashtray/cover (D). 3.5. Remove the screw (E) for the rear cover. 3.6. Remove the floor console's retaining nuts (E). 3.7. Detach the floor console (G) by pulling it straight back and lifting it slightly. 3.8. If required, detach the switch for the rear seat heater and unplug the connector. 4. Remove the switch and the floor console: 4.1. Detach the window lift module (A) by loosening it in the front edge (snap fastener). Unplug the window lift module's connector. 4.2. Detach the switch for the roof lighting (B) and unplug its connector. Lift away the floor console. 5. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: 5.1. Unplug the SRS control module's connector (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9288 5.2 Cut off the cable tie (B), detach the connector's rear end face (C) and pull out the connecting rail (D). 5.3. Remove pin 39, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 5.4. Fit the connecting rail and end face. 5.5. Plug in the connector (A) and secure the cables with cable ties (B). 6. Install the floor console over the handbrake. Do not press the console down into place, but instead allow it to fit loosely. 7. Install the switch: 7.1. Install the switch for the roof lighting (B) and plug in its connector. 7.2. Guide the connectors for the window lift module and rear seat heater, if equipped, through the hole for each respective unit. Plug in the window lift module's connector and install the module (A). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9289 7.3. If equipped, connect the rear seat heater's connector and install the switch. 8. Install the floor console: 8.1. Install the floor console's retaining bolts (C) and retaining nuts (F). 8.2. Align the rear cover; make sure that the air duct connects firmly to the air nozzle. Screw in the cover (E). 8.3. Install the ashtray/cover (D). 8.4. Install the ignition switch cover (B). 8.5. Plug in the immobilizer unit (A) connector. Install the unit, bayonet fitting. 9. Remove the OnStar(R) control modules and secure the wiring: 9.1. Remove the right-hand rear luggage compartment trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 9.2. Unplug the connectors (A) from the OnStar(R) control modules. 9.3. Remove the console (B) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9290 Important: Secure the wiring harness so that there is no risk of chafing and rattling. 9.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 9.5. Install the right-hand rear luggage compartment in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 10. Install the ground cable to the battery's negative terminal. 11. Clear the diagnostic trouble codes. 12. Set the date and time, see WIS - 3. Electrical system - Information display (SID_ - Technical description. 2003-2005 Saab 9-3 (9400) 4D/5D; 2004-2005 Saab 9-3 (9400) CV 2003-2005 Saab 9-3 (9440) 4D/5D; 2004-2005 Saab 9-3 (9440) CV Notice: Handle the fiber optic cables with care or the signal may be distorted. ^ It is very important that the two leads in the connector are not confused with one another. ^ Do not splice the cables. ^ Do not bend the cable in a radius smaller than 25 mm (1 in). ^ Do not expose the cable to temperatures exceeding 185°F (85°C). ^ Keep the cable ends free from dirt and grime. ^ Do not expose the cable to impact as this may cause the transparent plastic to whiten, thereby reducing the intensity of the light and causing possible communication interruptions. ^ The cable should not lie against any sharp edges as this may cause increased signal attenuation. 1. Remove the ECU CU with a Tech 2(R) according to the following: Fault diagnosis - Select model year - Select Saab 9-3 Sport (9440) - All - Add/Remove - Control Module - CU/PU - Remove. 2. Remove the ground cable from the battery's negative terminal. 3. Remove the floor console in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 4. Pry out the signal line from the SRS control module to the OnStar(R) control module and secure it: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9291 4.1. Unplug the SRS control module's connector (A). 4.2. Cut off the cable tie (B), detach the connector's rear end face (C), and pull out the connecting rail (D). 4.3. Extract pin 15, cut off the cable terminal and insulate the end with tape (E). Fold back the cable and secure it with tape (F). 4.4. Fit the connecting rail and end face. 4.5. Plug in the connector (A) and secure the cables with cable ties (B). 5. Remove the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6. M03: Replace the optic cable on the right-hand side Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9292 Important: Secure the wiring harness so that there is no risk of chafing or rattling. 6.1. Remove the passenger seat in accordance with WIS 8. Body - Seats Adjustment/Replacement. 6.2. Remove the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.3. Remove the right-hand C pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.4. Fold the rear seat backrest forward. 6.5. Remove the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.6. Remove the A-pillar's lower side piece. 6.7. Open the cover on the right-hand wiring harness channels. 6.8. Loosen the locking strip (A) on the 2-pin connector (H2-11) for the optic cable, located by the right-hand A-pillar. 6.9. Loosen the catch (B) and remove the optic cable that runs backward in the car. 6.10. Dismantle the end cap from the new optic cable (12 783 577) and connect it to the connector H2-11. Push in the optic cable and make sure the catch (B) locks and refit the locking strip (A). 6.11. Secure the connector and the old optic cable using the cable tie for the existing wiring harness (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9293 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.12. Place the optic cable in the wiring harness channels on the right-hand side. Thread through the existing cable ties (C) if possible, otherwise, secure with a cable tie to the existing one. Close the cover on the channels. Ensure the catches lock. 6.13. Secure the optic cable along the right-hand rear wheel housing, next to the ordinary wiring harness securing points and by the SRS unit (D). 6.14. Thread the optic cable up next to the safety belt by the old optic cable and place on the parcel shelf. 6.15. Unplug the connectors (E) from the OnStar(R) control modules. 6.16. Remove the console (F) together with the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9294 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 6.17. Fold back the wiring harness and tape over the connectors (G). Fold back the wiring harness once more and secure with cable ties (H). 6.18. Secure the new optic cable on the parcel shelf along the existing wiring harness by the ordinary securing points and by the speaker (I). 6.19. Thread the optic cable down next to the old cable from the parcel shelf to the left-hand wheel housing, next to REC. The cable is secured in the existing clips. 6.20. Fit the right-hand C-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.21. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.22. Fit the passenger seat in accordance with WIS - 8. Body - Seats - Adjustment/Replacement. 6.23. Fit the right-hand side bolster in accordance with WIS - 8. Body - Seats Adjustment/Replacement. 6.24. Fold up the rear seat backrest. 6.25. Fit the right-hand B-pillar trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 6.26. Fit the A-pillar's lower side piece. 7. M04-05, 4D: Removing the OnStar® control modules and securing the wiring: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9295 7.1. Remove the console (A) together with the OnStar(R) control modules. 7.2. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 7.3. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). 7.4. Fit the parcel shelf trim in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. 8. CV: Removing the OnStar(R) control modules and securing the wiring: Adjustment/Replacement. 8.1. Open the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9296 8.2. Remove the console (A) together with the OnStar(R) control modules. 8.3. Remove the connectors (B). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 8.4. Fold back the wiring harness and tape over the connectors (C). Fold back the wiring harness once more and secure with cable ties (D). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9297 8.5. Close the luggage compartment floor. 9. Fold down the left-hand rear side hatch in the luggage compartment. 10. M03: Replace the optic cable on the left-hand rear side: 10.1. Place the optic cable so that it is positioned behind the terminal housing on top of REC (A). 10.2. Remove the locking strip (B) on the 2-pin connector (H2-9) for the optic cable. 10.3. Open the terminal housing (C) with a screwdriver. Remove the secondary catch (D) on the connector and disconnect the optic cable coming from the OnStar(R) control modules. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9298 10.4. Remove the end cap from the new optic cable, connect to the connector and refit the secondary catch (D). Fit the terminal housing (C) to the connector and refit the locking strip (B). 10.5. Secure the old optic cable together with the new one (E). Important: The optic cable must not be bent with a radius less than 25 mm (1 in). Important: Secure the wiring harness so that there is no risk of chafing and rattling. 11. CV: Remove the rear seat in accordance with WIS - 8. Body - Interior equipment Adjustment/Replacement. The O-bus connector H2-9 is located behind the left speaker. 12. M04-05: Disconnect the optic cables on the OnStar(R) control modules and join the cables: 12.1. Cut off the cable tie holding the connector (H2-9) against REC. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9299 12.2. Cars with brackets for e.g. an amplifier: Remove the pin strap (A) from the bracket and remove the tape (B) holding the optic cables. 12.3. Remove the locking strip (C) on the 2-pin connector (H2-9). Open the terminal housing with a screwdriver. Remove the secondary catch (E) on the connector and remove the optic cables coming from the OnStar(R) control modules. 12.4. Loosen one of the optic cables remaining in H2-9 (F), connect it to the connector and fit the secondary catch (E). Connect the connector so that the optic cables are opposite each other (G). Connect the terminal housing (D) and refit the locking strip (C). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9300 Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.5. Cars with brackets for e.g. an amplifier: Fit the cable tie (11 900 515) to the wiring harness approx. 100 mm (4 in) from H2-9, fit the cable tie (H) to the bracket. Gather the optic cable in a gentle loop (I) and then place the loop behind the bracket. Important: The optic cable must not be bent with a radius less than 25 mm (1 in). 12.6. Cars without brackets for e.g. an amplifier: Gather the optic cable in a gentle loop (J) and secure with cable tie. 13. CV: Fit the left-hand, rear side hatch trim in accordance with WIS - 8. Body - Interior equipment - Adjustment/Replacement. 14. Fit the ground cable to the battery's negative terminal. 15. Carry out procedures after disconnecting the battery, see WIS - 3. Electrical System - Charging system - Adjustment/Replacement. Important: Follow Tech 2(R) on-screen instructions. 16. Add ECU ICM, choose without OnStar(R). See WIS-General-Tech 2(R) - Description and Operation - Add/Remove. 2000-2004 Saab 9-5 2000-2004 Saab 9-5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9301 1. Remove the ground cable from the battery's negative cable. 2. Remove the center console, see WIS - Body - Interior. 3. Loosen the gear shift housing (A). AUT: Disconnect the 6-pin connector (B) to improve access to the gear shift housing screws. 4. Disconnect the signal cable from the SRS control module to the OnStar(R) control module and secure the cable. 4.1. Disconnect the connector (A) from the SRS control module and cut the cable tie (B). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9302 4.2. Release the back end of the connector (C) and remove from the contact rail (D). 4.3. M00-01: Disconnect pin 39, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.4. M02-04: Disconnect pin 58, cut off the cable terminal and insulate the end using tape (E). Fold back the cable and secure using tape (F). 4.5. Assemble the contact rail and end. 4.6. Connect connector (A) and secure the cable using a cable tie (B). 5. Assemble the gear shift housing (A). AUT: Connect connector (B). 6. Assemble the center console, see WIS - Body - Interior. 7. Remove the OnStar(R) control module and secure the cable harness: 7.1. 5D: Remove the right-hand cover from the luggage compartment floor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9303 7.2. Remove the console (A). 7.3. Disconnect the connector (B) from the OnStar(R) control module. Important: Secure the cable harness to prevent the risk of scraping and rattling. 7.4. Fold back the cable harness and tape down the connector (C). Fold back the cable harness again and secure with cable ties (D). 7.5. 5D: Assemble the right-hand cover for the luggage compartment floor. 8. Fit the ground cable on the battery's negative cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 08089C > Nov > 08 > Campaign - Deactivation Of Analog OnStar(R) > Page 9304 9. Erase the diagnostic trouble codes. 10. Set the date and time, see WIS - 3. Electrical system - Information display (SID) - Technical description. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9309 ^ Pay the dealer the regular retail price (no discounts are available) for one of the following 1-year, non-refundable OnStar(R) Analog-to-Digital Transition (ADT) Service Subscription Plans: ^ 1-year Safe & Sound Subscription: $199 ($289 in Canada) ^ 1-year Directions & Connections Subscription: $399 ($579 in Canada) ^ Pay the dealer the applicable state and local sales taxes on the subscription: ^ U.S. Dealers: Taxes only apply in these states: CT, DC, FL, HI, ND, NJ, NM, NY, SC, SD, TX, and WV ^ Canadian Dealers: All applicable taxes ^ Pay the dealer a one-time charge of $15 for the upgrade: ^ U.S. Dealers: Do not collect taxes on the $15 ^ Canadian Dealers: Collect all applicable taxes on the $15 Note: Dealers should NOT remit OnStar(R) ADT-related taxes to their taxing authority as OnStar(R) is responsible for tax remittance. Please Be Sure To Read these Important Points: ^ The 1-year OnStar(R) subscription is not refundable or transferable to another person. Upgraders can apply unused subscription months to a new or Certified Pre-Owned digital OnStar-equipped GM vehicle purchase or lease. As noted above, the digital upgrade program requires the subscriber to purchase a one-year prepaid OnStar(R) subscription. Assuming the subscriber intends to keep their vehicle, but subsequently purchases or leases a 2006 model year or newer OnStar(R)-equipped new or certified used GM vehicle, in the interest of subscriber satisfaction, they may apply remaining unused whole months of the subscription to the new vehicle. The subscription may not be applied to another person's vehicle. Important: This is a customer satisfaction measure that would usually occur several months after an upgrade. It is not intended to be leveraged as part of a new/used vehicle purchase or lease transaction. ^ The $15 charge is not refundable. ^ Dealer ADT kit orders are VIN specific. Dealer kit orders require a VIN and must be exchanged with the OnStar(R) unit in the vehicle with that VIN. Proper activation and enrollment depends on this step. ^ You must put the actual miles on the Repair Order. Do not estimate. ^ Customers will receive a Hands-Free Calling number once the digital hardware is installed and configured. ^ Any nametags that were stored in the old system will need to be re-set by the subscriber once the new hardware is installed. ^ Customers are responsible for the charges described above regardless of whether their vehicle is in or out of the New Vehicle Warranty period. In addition, customers should not be charged labor costs. Dealers can charge GM the labor for the upgrade as specified at the end of this bulletin using the listed labor operation. ^ Vehicles eligible for an OnStar(R) hardware upgrade are listed in this bulletin. Vehicle upgradeability can also be determined by typing the VIN into the field entitled "Determine VIN Hardware Functionality" on the OnStar(R) Online Enrollment website, located in the sales or service workbench tab of GM GlobalConnect. Canadian Dealers can use a similar tool that is available within InfoNET. ^ Access to the sales and/or service workbench in the GM GlobalConnect website can be granted by the dealership's Partner Security Coordinator (PSC). If you are unsure who the PSC is, check with the Sales Manager. Ordering the Upgrade Kit/Upgrade kit Installation Ordering the Upgrade Kit 1. To order a kit, you will need to access the OnStar(R) Online Enrollment webpage, located under the sales or service workbench of GM GlobalConnect (infoNET for Canadian upgrade orders). These kits cannot be ordered from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9310 2. Click on the Analog-to-Digital Program link to start the ordering process. 3. To order a kit, you will need the information shown above. 4. After submitting the order, the "Terms and Conditions of Your OnStar(R) Service" page will display. This is your confirmation that the upgrade kit order has been created. U.S. Dealers will also receive an e-mail from Autocraft within several hours of ordering an upgrade kit (Canadian Dealers will receive an e-mail from MASS Electronics). 5. Print the "Terms and Conditions of Your OnStar(R) Service" page, and have the customer sign a copy. 6. A copy of this form should be stapled to the customer's copy of the Repair Order and one copy should be retained in the customer service folder. 7. If the kit you ordered is available, you will receive the upgrade kit within 4 business days of entering your order through the OnStar(R) Online Enrollment webpage. 8. To check on kit availability or the status of your order, U.S. Dealers can log onto the distributor's website at www.autocraft.com. Canadian dealers can call MASS Electronics at 877-410-6277. Upgrade Kit Installation 1. Skip to the next step if the vehicle to be upgraded is not shown above. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9311 2. Skip to the next step if the vehicle to be upgraded is not shown above. 3. Skip to the next step if the vehicle to be upgraded is not a 2005 Cadillac STS. The 2005 Cadillac STS kit may include a new inside rearview (ISRV) mirror assembly and a new ISRV mirror wiring cover. If the kit you receive includes these parts, please remove the existing ISRV mirror and wire cover from the vehicle and install the ones provided in the kit per the instructions in SI. 4. Skip this step if the vehicle to be upgraded is not listed below. ^ 2003-2004 Saturn L-Series ^ 2003 Saturn ION ^ 2002-2003 Saturn VUE 1. Locate and remove the Right Audio output signal terminal 7 from Connector C2 at the Vehicle Communication Interface Module (VCIM). 2. Remove the terminal end and strip the wire. 3. Locate the Left Audio output signal wire from terminal 1 in Connector C2. 4. Splice the Right Audio output signal wire from terminal 7 with the Left Audio output signal wire from terminal 1. 5. See Wiring Repairs in SI for approved splicing methods. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9312 6. See wiring diagram shown above for details. 5. Replace the OnStar(R) Vehicle Communication Interface Module (VCIM) in the vehicle with the provided Digitally-Capable VCIM. Refer to the Communication Interface Module Replacement procedure in the Cellular Communication section of SI. This kit may include a new VCIM bracket. If it does, use this new bracket on the vehicle and discard the original bracket. The kit may also include a small wiring jumper cable. If it does, plug the wiring jumper cable into the connector on the VCIM and the other end to the corresponding vehicle wiring harness connector. ^ For 2001, 2002 and 2003 Chevrolet Impala and Monte Carlo, do not reinstall the black plastic OnStar(R) module cover onto the vehicle after the VCIM and module bracket have been installed. This black plastic cover will no longer fit on the vehicle. ^ The upgrade kit for 2002 Sevilles and DeVilles, and some 2003 Sevilles and DeVilles, will contain a large bracket. To install the new VCIM into this bracket you'll need to carefully line up the notch in the VCIM with the tab in the bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9313 ^ On 2002 Sevilles and DeVilles, the GPS jumper cable MUST be unclipped from the back seat cross brace, or unplugged from the VCIM first. DO NOT pull back on the mounting bracket until the GPS antenna jumper cable is unclipped from the back seat cross brace or unplugged from the VCIM. The short length of jumper cable does not allow the VCIM mounting bracket to be pulled back very far, and could lead to a break at the VCIM connector. ^ On 2000-2002 Bonnevilles and LeSabres and 2001-2002 Auroras you will need to follow these steps: 1. Remove the 4 nuts that secure the VCU/VIU bracket assembly to the rear seat back brace. Note: Save these nuts for later use. 2. Remove and discard the plastic VCU/VIU bracket assembly from the vehicle. 3. Remove the upper right stud (1) from the rear seat back brace and re-install in the middle lower slot (2) on the brace. Tighten the fastener to 4 Nm (36 lb in). 4. Position the new VCIM in the vehicle over the studs on the rear seat back brace. 5. Install two of the nuts saved from step (1). Tighten the nuts to 4 Nm (36 lb in). 6. Connect the new OnStar jumper harness supplied in the kit to the VCIM (two white connectors) and the body wiring harness (C345 connector). 7. Connect the small coaxial jumper cable supplied in the kit, to the VCIM, with the end that has a blue plastic housing connector. Plug the other end of this coaxial jumper cable to the OnStar Global Positioning Satellite (GPS) antenna coaxial cable at the right angle connector. Note: The GPS cable in the new OnStar jumper harness is not utilized. 8. Connect the cellular coaxial cable to the OnStar VCIM. On 2001 Impala and Monte Carlos you will need to follow these steps: 9. Remove the Vehicle Communications Unit (VCU) and Vehicle Interface Unit (VIU) following the procedures listed in SI. Save the bracket nuts for later use. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9314 10. Disconnect and remove the OnStar(R) jumper harness. Note: You will need to remove the short GPS cable from this jumper harness. 11. Untape the cell antenna coax from the body harness in the trunk. This will be necessary to provide adequate length to connect to the new VCIM. 12. Fasten three retainer clips (1) from the kit to the new bracket that is included in the kit, and position the VCIM to the bracket (2). 13. Install the three bolts from the kit. Tighten the bolts to 10 Nm (89 lb in). 14. Connect the new OnStar(R) jumper harness supplied in the kit to the VCIM (two white connectors on module). 15. Connect small GPS coax cable jumper harness supplied in the kit (end with blue plastic housing) to VCIM GPS connector. 16. Position the VCIM / bracket assembly to the studs. 17. Install the bracket nuts saved from the Removal Procedure above to the VCIM / bracket assembly mounting studs. Tighten the nuts to 4 Nm (35 lb in). 18. Connect the new OnStar(R) jumper harness to the body wiring harness (C410 connector). 19. Connect small coax cable jumper from VCIM to the OnStar(R) Global Positioning Satellite (GPS) antenna coaxial cable at the connector previously left in the vehicle (short jumper removed from old harness in step 5.10). 20. Connect the cellular coaxial cable previously left in vehicle to the OnStar(R) VCIM. 21. Verify that all harnesses are properly secured in vehicle. 6. After replacing the VCIM, it is essential to configure the new OnStar(R) system. Failure to configure the system will result in an additional customer visit for repair. DO NOT press and hold the white dot or phone button on the keypad as it will not reset this version of the OnStar(R) system and may result in a DTC being set. Use of the TIS2WEB and SPS applications, along with the Tech2(R), are required in order to perform the VCIM configuration and setup procedure for this vehicle. The configuration and set-up procedure is now a two-step process which enables an automated activation by the OnStar(R) Center, without a button press by the technician to the OnStar(R) Call Center. 1. Connect the Tech2(R) to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9315 2. Connect the Techline Information System (TIS) terminal to the Tech2(R). 3. Scroll to the bottom of the Controller List, and select the "ONSA TIS2WEB Pass-Thru OnStar(R) Activation (Replaced/Upgraded Units Only)" option using the Service Programming System (SPS). Important: Do not use the clear DTC function. This will only temporarily turn the LED to green. 4. Upon completion of the OnStar(R) TIS2WEB step, disconnect the TIS terminal from the Tech2(R) and perform the VCIM/OnStar(R) Set-up Procedure using the Tech2(R). The set up procedure is located under the special function menu option. Important: Failure to perform the above steps will result in a red LED, DTC being set and limited or incomplete OnStar(R) services, and will require a customer return visit to the dealership. 5. The default language for the new VCIM will be English. To change to French or Spanish, access the special functions menu on the Tech 2(R), and follow the instructions accordingly. 7. Skip to the next step if the vehicle to be upgraded is not listed below: ^ 2002-2004 Cadillac DeVille ^ 2002-2004 Cadillac Seville ^ 2005 Cadillac STS Set up the Dash Integration Module (DIM) using the following procedure: 1. On the Tech2(R) select the correct Year, Make and Model. 2. Enter Dash Integration Module (DIM) > Special Functions > Set Options > Misc. Options 1 > and turn off phone (if the vehicle does not have the UV8 option). 3. Enter Nav Radio Present and set to "No Nav" (if the vehicle does not have a navigation radio). 4. Turn the ignition off and open the door to turn off the RAP. 5. Turn the ignition on and enter the Vehicle Comm. Interface Module > Special Functions > Set Up OnStar /VCIM. 6. When prompted select "No Phone" (if the vehicle does not have the UV8 phone) and "No Nav" (if the vehicle does not have a navigation radio). 7. Turn the ignition off and open the door to turn off the RAP. Important: OnStar(R) Emergency Services are immediately available after these steps, however, full configuration, including activation of Hands-Free Calling, may take up to 24 hours to complete. Processing the Module Exchange Processing the Module Exchange For this program, submitting a credit request for the removed OnStar(R) VCIM (the core) will be performed through a website. When this process is followed, the removed Analog / Digital-Ready VCIM, in most cases, will not be mailed back to the distributor, but can be scrapped by the dealership. U.S. Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto www.autocraft.com. 3. Select Account Maintenance. 4. Select Outstanding Cores. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9316 5. Choose the outstanding core you wish to process, by selecting the Virtual Core Button on the far right side of the screen. 6. Enter the information in the required fields and select the submit button. Record the confirmation number. Canadian Dealers 1. Return the removed Analog / Digital-Ready OnStar(R) VCIM to the Parts Manager. 2. The Parts Manager will log onto https://adt.onstar.gm.mass.ca and enter information as prompted. All Dealers If the website indicates that the VCIM needs to be physically returned to the distributor, please use the pre-paid shipping label that was included in the kit to return the removed VCIM. Important: To avoid a $250 core non-return charge, you must do one of the following within 30 days of kit shipment: 1. Submit the necessary VCIM data through the website, as indicated above. 2. Mail the removed core from the customer's vehicle back to the distributor. 3. Return the unused digital upgrade kit back to the distributor using the pre-paid shipping label that is included in the kit box. Returning the Upgraded Vehicle to the Customer Returning the Upgraded Vehicle to the Customer 1. Place the new OnStar Subscriber Information (Owner's Manual kit) in the customer's vehicle where they can review some of the new features of the Digital-Capable system. The continuous digit dialing feature should be highlighted to the customer to avoid a return to the dealership for dialing instructions. Advise the customer to discard any existing OnStar(R) Owner's Manuals that may be in the vehicle. 2. Have the Service Advisor, Service Manager or Sales Consultant review the new OnStar(R) Hands-Free Calling procedure with the customer. The customer is uses to their analog OnStar(R) Hands-Free Calling system, which uses individual digit dial to make a call. The Generation 6 Digital-Capable system uses continuous digit dial, and the customer needs to be made aware of this change. 3. U.S. Dealers Only: Staple the "Tip Sheet - OnStar(R) Generation 6 Digitally-Capable System", that was included in the kit, to the customer's copy of the repair order. This tip sheet will help your customer better understand their new OnStar(R) system. 4. Canadian Dealers Only: Refer the customer to the Hands-Free Calling Quick Review Card from the new OnStar(R) Owner's Manual kit for help with the new dialing procedure. 5. Fill out the form entitled "GM Limited Warranty for Upgraded OnStar(R) Digital Equipment Program Participants" and staple a copy of this to the customer's repair order. You may want to keep a copy for your records. 6. Encourage your customer to press their blue OnStar(R) button the next day. The OnStar(R) Advisor will be able to review some of the new features of their digital OnStar(R) system. Closing the Onstar(R) Upgrade Exchange Closing the OnStar(R) Upgrade Exchange 1. Collect payment from the customer. Your dealership's open account (sales) will be charged for the cost of the chosen subscription plan, any applicable subscription taxes, and the $15 upgrade charge after the vehicle has been configured through the TIS2WEB process. 2. None of the costs associated with the OnStar Digital Upgrade program may be claimed as a GM goodwill event. These costs must be paid by the customer, and may not be included in any goodwill offered to the customer. GM employees or representatives or field personnel are not able to offer goodwill for this program. If the dealership decides to pay for the upgrade for their customer, be aware that your GM or OnStar(R) contact will not be able to reimburse you for this cost. 3. Use labor code Z2096 to submit your claim for the labor time published below plus 0.2 hr Administrative Allowance and an additional $20.00 Net Amount. ^ For all dealer claim submissions (excluding U.S. Saturn), use Complaint Code MH - Technical Bulletin, and Failure Code 93 - Technical Service Bulletin. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9317 ^ For U.S. Saturn retailer claim submission, use Net Item code "M" and Case Type VW. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9318 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9319 Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 05-08-46-006Q > Oct > 08 > OnStar(R) - Analog/Digital Ready System Digital Upgrade > Page 9320 Labor Time Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Emergency Contact Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Emergency Contact Module: > 06-08-46-008C > Sep > 08 > OnStar(R) - Analog/Digital System Information > Page 9325 networks, and will not require an upgrade in connection with the cellular industry's transition to the digital network. In order to verify the type of OnStar(R) Hardware in a vehicle, type the VIN into the VIN look-up tool, which is available at the OnStar(R) Online Enrollment website within GM GlobalConnect (for U.S. dealers) or InfoNet (for Canadian dealers). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair Global Positioning System Module: Service and Repair COMMUNICATION INTERFACE MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: The vehicle communication interface module (VCIM) has a specific set of unique numbers that tie the module to each vehicle. These numbers, the 10-digit station identification and the 11-digit electronic serial number, are used by the National Cellular Network and OnStar(R) to identify the specific vehicle. Because these numbers are tied to the vehicle identification number of the vehicle, you must never exchange these parts with those of another vehicle. 1. Open the rear compartment. 2. Remove the communication interface module cover. 3. Remove the bracket nuts from the communication interface module. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair > Page 9337 4. Adjust the assembly for access. 5. Disconnect the cellular antenna cable from the communication interface module. 6. Disconnect the electrical connectors from the module. 7. Disconnect the GPS antenna cable from the module. 8. Remove the bolts (1) from the communication interface module. 9. Remove the communication interface module (2). INSTALLATION PROCEDURE 1. Record the 11-digit electronic serial number (ESN) and the 10-digit station identification (STID) number from the label on the new VCIM. 2. Position the communication interface module to the bracket (2). NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the communication interface module bolts (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair > Page 9338 Tighten Tighten the bolts to 10 N.m (89 lb in). 4. Connect the GPS antenna cable to the module. 5. Connect the electrical connectors to the module. 6. Connect the cellular antenna cable to the module. IMPORTANT: After replacing the communication interface module, you must reconfigure the OnStar(R) system. Failure to reconfigure the system will result in an additional customer visit for repair. 7. Reconfigure the OnStar(R) system. Refer to OnStar Reconfiguration. 8. Position the assembly to the studs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Global Positioning System Module > Component Information > Service and Repair > Page 9339 9. Install the bracket nuts to the communication interface module. Tighten Tighten the nuts to 4 N.m (35 lb in). 10. Install the communication interface module cover. 11. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9348 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9349 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9350 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9356 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9357 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9358 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules Relay Module: Customer Interest Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9367 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9368 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > Customer Interest for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical - MIL ON/DTC's Set By Various Control Modules > Page 9369 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules Relay Module: All Technical Service Bulletins Electrical - MIL ON/DTC's Set By Various Control Modules TECHNICAL Bulletin No.: 09-06-03-004D Date: December 08, 2010 Subject: Intermittent No Crank/No Start, No Module Communication, MIL, Warning Lights, Vehicle Messages or DTCs Set by Various Control Modules - Diagnosing and Repairing Fretting Corrosion (Disconnect Affected Connector and Apply Dielectric Lubricant) Models: 2011 and Prior GM Passenger Cars and Trucks Attention: This repair can be applied to ANY electrical connection including, but not limited to: lighting, body electrical, in-line connections, powertrain control sensors, etc. DO NOT over apply lubricant to the point where it prevents the full engagement of sealed connectors. A light coating on the terminal surfaces is sufficient to correct the condition. Supercede: This bulletin is being revised to update the Attention statement and add the 2011 model year. Please discard Corporate Bulletin Number 09-06-03-004C (Section 06 Engine/Propulsion System). Condition Some customers may comment on any of the following conditions: - An intermittent no crank/no start - Intermittent malfunction indicator lamp (MIL) illumination - Intermittent service lamp illumination - Intermittent service message(s) being displayed The technician may determine that he is unable to duplicate the intermittent condition. Cause This condition may be caused by a buildup of nonconductive insulating oxidized debris known as fretting corrosion, occurring between two electrical contact surfaces of the connection or connector. This may be caused by any of the following conditions: - Vibration - Thermal cycling - Poor connection/terminal retention - Micro motion - A connector, component or wiring harness not properly secured resulting in movement On low current signal circuits this condition may cause high resistance, resulting in intermittent connections. On high current power circuits this condition may cause permanent increases in the resistance and may cause a device to become inoperative. Representative List of Control Modules and Components The following is only a representative list of control modules and components that may be affected by this connection or connector condition and DOES NOT include every possible module or component for every vehicle. - Blower Control Module - Body Control Module (BCM) - Communication Interface Module (CIM) - Cooling Fan Control Module - Electronic Brake Control Module (EBCM) - Electronic Brake and Traction Control Module (EBTCM) - Electronic Suspension Control (ESC) Module - Engine Control Module (ECM) - Heating, Ventilation and Air Conditioning (HVAC) Control Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 9375 - HVAC Actuator - Inflatable Restraint Sensing and Diagnostic Module (SDM) - Any AIR BAG module - Seatbelt Lap Anchor Pretensioner - Seatbelt Retractor Pretensioner - An SIR system connection or connector condition resulting in the following DTCs being set: B0015, B0016, B0019, B0020, B0022, or B0023 - Powertrain Control Module (PCM) - Remote Control Door Lock Receiver (RCDLR) - Transmission Control Module (TCM) Correction Important DO NOT replace the control module, wiring or component for the following conditions: - The condition is intermittent and cannot be duplicated. - The condition is present and by disconnecting and reconnecting the connector the condition can no longer be duplicated. Use the following procedure to correct the conditions listed above. 1. Install a scan tool and perform the Diagnostic System Check - Vehicle. Retrieve and record any existing history or current DTCs from all of the control modules (refer to SI). ‹› If any DTC(s) are set, refer to Diagnostic Trouble Code (DTC) List - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). ‹› If DTCs are not set, refer to Symptoms - Vehicle to identify the connector(s) of the control module/component which may be causing the condition (refer to SI). 2. When identified, use the appropriate DTC Diagnostics, Symptoms, Schematics, Component Connector End Views and Component Locator documents to locate and disconnect the affected harness connector(s) which are causing the condition. Note Fretting corrosion looks like little dark smudges on electrical terminals and appear where the actual electrical contact is being made. In less severe cases it may be unable to be seen or identified without the use of a magnifying glass. Important DO NOT apply an excessive amount of dielectric lubricant to the connectors as shown, as hydrolock may result when attempting to mate the connectors. Use ONLY a clean nylon brush that is dedicated to the repair of the conditions in this bulletin. 3. With a one-inch nylon bristle brush, apply dielectric lubricant to both the module/component side and the harness side of the affected connector(s). 4. Reconnect the affected connector(s) and wipe away any excess lubricant that may be present. 5. Attempt to duplicate the condition by using the following information: - DTC Diagnostic Procedure - Circuit/System Description - Conditions for Running the DTC - Conditions for Setting the DTC - Diagnostic Aids - Circuit/System Verification ‹› If the condition cannot be duplicated, the repair is complete. ‹› If the condition can be duplicated, then follow the appropriate DTC, Symptom or Circuit/System Testing procedure (refer to SI). Repair Order Documentation Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 9376 Important The following information MUST be documented on the repair order. Failure to do so may result in a chargeback. - Customer vehicle condition. - Was a Service Lamp or Service Message illuminated? If yes, specify which Service Lamp or Service Message. - Was a DTC(s) set? If yes, specify which DTC(s) were set. - After following the procedure contained within this bulletin, could the condition be duplicated? ‹› If the condition was not duplicated, then document the affected module/component connector name and number on the repair order. - If the condition was duplicated after the procedure contained within this bulletin was followed, and additional diagnosis led to the replacement of a module or component, the SI Document ID Number MUST be written on the repair order. Parts Information Alternate Distributor For All of North America Note NyoGel(R) 760G Lubricant* is equivalent to GMSPO P/N 12377900, and P/N 10953529 (Canada), specified for use to correct the condition in this bulletin. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Warranty Information (excluding Saab Models) For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to: Warranty Information (Saab Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Relay Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Relay Module: > 09-06-03-004D > Dec > 10 > Electrical MIL ON/DTC's Set By Various Control Modules > Page 9377 For vehicles repaired under warranty, use the appropriate/closest labor operation depending upon the module/component connection that the dielectric lubricant was applied to refer to the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams Passlock Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Lock Cylinder Switch > Component Information > Diagrams > Page 9382 Lock Cylinder Switch: Description and Operation PASSLOCK(TM) SENSOR The Passlock(TM) sensor contains 2 hall effect sensors. The tamper hall effect sensor is on the top. The security hall effect sensor is under the tamper hall effect sensor. Both of the hall effect sensors monitor the magnet of the lock cylinder through an opening. The tamper hall effect sensor is physically placed on top of the security hall effect sensor. This arrangement enables the tamper hall effect sensor to engage first if an intruder attempts to bypass the Passlock(TM) sensor by placing a large magnet around that area of the steering column. There is a tamper resistor inside the Passlock(TM) sensor in order to help prevent tamper to the system. Passlock(TM) equipped vehicles have a selection of 10 different security resistors ranging from 0.5K ohms up to 13.6K ohms. Installing one of the security resistors inside the Passlock(TM) sensor will generate a unique Passlock(TM) code. All 10 combinations of the Passlock(TM) sensor have the same part number. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Remote Switch, Audio - Stereo > Component Information > Technical Service Bulletins > Audio - Inadvertent Steering Wheel Button Activation Remote Switch: Technical Service Bulletins Audio - Inadvertent Steering Wheel Button Activation INFORMATION Bulletin No.: 08-08-44-028 Date: August 28, 2008 Subject: Information On Inadvertent Steering Wheel Control (SWC) Button Press Causing Radio Anomalies Models: 2009 and Prior GM Passenger Cars and Trucks (Including Saturn) 2009 and Prior HUMMER H2, H3 Models 2009 and Prior Saab 9-7X All Vehicles with Steering Wheel Controls This bulletin is being issued to provide a recommendation for vehicles with a customer concern of the radio station tuning changing by itself, volume changing by itself, radio changing by itself, or radio muting or going silent when driving and turning the steering wheel. The switches on the right hand side of the steering wheel are easily pressed and may inadvertently be pressed when turning the steering wheel. These concerns may be affected by the location of the steering wheel controls. Recommendation Do Not Replace The Radio 1. Please determine that the switch controls on the steering wheel are functioning correctly. 2. Ask the customer if their hand was in close proximity to the steering wheel controls when the condition happened. Explain to the customer that bumping the controls would have caused this undesired action. Explain to the customer the proper use and function of the steering wheel controls. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions Steering Mounted Controls Transmitter: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9391 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9392 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9393 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9394 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9395 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9396 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9397 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9398 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9399 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9400 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9401 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9402 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9403 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9404 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9405 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9406 Steering Mounted Controls Transmitter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9407 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9408 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9409 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9410 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9411 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9412 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9413 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9414 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9415 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9416 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9417 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9418 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9419 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9420 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9421 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9422 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9423 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9424 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9425 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9426 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9427 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9428 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9429 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9430 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9431 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9432 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9433 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Diagram Information and Instructions > Page 9434 Steering Mounted Controls Transmitter: Electrical Diagrams Steering Wheel Controls Diagram Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 9435 Steering Mounted Controls Transmitter: Service and Repair Steering Wheel Control Switch Assembly Replacement (Impala) Removal Procedure 1. Disable the SIR system. 2. Remove the inflatable restraint steering wheel module. 3. Remove the steering wheel. 4. Remove the steering wheel controls wire harness from the retainers in the aluminum insert and plastic back shroud. 5. Remove the back shroud screws and the back shroud on the back of the steering wheel. 6. Carefully push on the back of the steering wheel radio control switch through the access opening in the back of the steering wheel switch pocket. 7. Disconnect the electrical connector from the back of the steering wheel radio control switch. 8. Remove the radio control switch from the steering wheel. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Accessories and Optional Equipment > Steering Mounted Controls Transmitter > Component Information > Diagrams > Page 9436 1. Position the radio control switch to the steering wheel. Route the radio control wire harness through the access opening in the back of the steering wheel switch pocket. 2. Connect the electrical connector to the back of the steering wheel radio control switch. 3. Carefully install the radio control switch into the steering wheel switch pocket. Important: The steering wheel switch wiring harness must be kept below the white insulators on the back of the steering wheel when installing the plastic back shroud. Do not pinch the wire harness between the steering wheel urethane and the plastic back shroud. 4. Install the plastic back shroud to the back of the steering wheel with the shroud screws. 5. Install the radio controls wiring harness to the retainers in the steering wheel insert and back shroud. Verify that the wiring is not routed underneath any of the four SIR module mounting holes in the steering wheel. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the shroud screws and the shroud on the back of the steering wheel. ^ Tighten the screws to 2 Nm (18 in. lbs.). 7. Install the steering wheel. 8. Install the inflatable restraint steering wheel module. 9. Enable the SIR system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: Customer Interest BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 9447 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set Body Control Module: All Technical Service Bulletins BCM - Security Lamp ON/No Crank/DTC's Set Bulletin No.: 04-08-47-003 Date: August 31, 2004 TECHNICAL Subject: Security Light On, Engine Will Not Crank, Diagnostic Trouble Codes B2958 and/or B2960 (Repair Poor Terminal Connections at Body Control Module ) Models: 2000-2005 Chevrolet Impala, Monte Carlo Condition Some customers may comment on an engine that will not crank. Others may comment on the security light being on. Technicians may find DTCs (diagnostic trouble codes) B2958 and/or B2960. Cause These conditions may have several different causes. In each case, however, testing of the BCMs (Body Control Modules) replaced for these conditions are frequently found to be operating to specifications and are believed to have been replaced needlessly. A change was made to the BCM hardware in February of 2003. An updated BCM can be identified by a GMAN169 or higher number found on the BCM part label. This hardware change was made to prevent the remote possibility that a BCM, built after the GMAN169 number, could be the cause of these conditions. Correction The following are the likely causes of these conditions: 1. Damaged or loose/unseated terminals in these BCM connectors may cause a security light or no start condition: ^ BCM connector C1 (24-way, pink in color), terminal B9 (white wire, circuit 1459) ^ BCM connector C1 (24-way, pink in color), terminal B12 (black wire, circuit 1835) ^ BCM connector C2 (24-way, grey in color), terminal A3 (yellow wire, circuit 1836) Important: Use only approved tools for removal and testing of terminals. Do not use unapproved tools to probe a terminal as this could cause damage. Use Probe Tool J 35616-6, from the J 35616-B terminal test kit, to test the terminals in the BCM connector. 2. Check all the terminals in both BCM connectors, focusing on the three terminals listed above, for damage and proper seating of the terminal in the connector. If no damage is noted, follow the normal SI diagnostic procedures including clearing codes and attempting to duplicate the concern. 3. Always check for and clear all DTCs after recharging or disconnecting the battery. Attempt to restart the vehicle only after all DTCs have been cleared. This will help prevent an unnecessary BCM replacement due to false DTCs being set while servicing the battery. 4. A BCM should not be replaced when DTCs U1016 and/or U1064 have been set, even though the BCM is turning on the security light. Diagnose and repair or replace components as directed by the diagnostic procedures for these diagnostic trouble codes. 5. A current or history diagnostic trouble code B2958 in the BCM and a loss of battery voltage due to a battery going dead or a battery disconnect may cause a no start condition upon recharging or reconnecting the battery. Clearing the diagnostic trouble code will allow the vehicle to start. 6. The security light may turn on when the IPC (Instrument Panel Cluster) or PCM (Powertrain Control Module) does not receive a state of health message from the BCM within a specified window of time. DTCs U1016 or U1064 may set. Upon receiving the state of health message again, the security light will go out and diagnostic trouble codes will go to history. If this happens frequently, the vehicle may exhibit an intermittent or random flash of the security light. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-47-003 > Aug > 04 > BCM - Security Lamp ON/No Crank/DTC's Set > Page 9453 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Body Control Module: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Body Control Module: > 04-08-52-001 > Feb > 04 > Keyless Entry - BCM Set-Up Programming Body Control Module: All Technical Service Bulletins Keyless Entry - BCM Set-Up Programming Bulletin No.: 04-08-52-001 Date: February 25, 2004 INFORMATION Subject: Set-up/Programming BCM for Remote Keyless Entry (RKE) Models: 2000-2004 Chevrolet Impala, Monte Carlo In the past, when replacing the BCM on the above listed vehicles, the module had to be set-up to ensure the RKE was initiated. The RKE option RPO may not have been called out individually on the SPID label when the RKE option was part of an option package. This would often lead to this option being missed during BCM set-up and leading to an inoperative RKE feature. The new BCM, P/N 10350647, currently available, will automatically toggle the RKE function on during initiation of the module. Therefore, it is no longer necessary to turn on the RKE. Just leave it on regardless if the vehicle is equipped with RKE or not. This will prevent an incorrect set-up causing this feature to become inoperative. This new BCM will also remedy a situation where some older BCMs would not remember the horn chirp setting, short or long, after going into sleep mode. Also, this new BCM will not lock the settings until after 32 key cycles compared to 15 key cycles on older BCMs. So, if a mistake is made during the initial set-up, you can re-set the module. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Technical Service Bulletins > Page 9463 Behind Left Side Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 Body Control Module: Diagrams Body Control Module (BCM) C1 Body Control Module, C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 9466 Body Control Module, C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 9467 Body Control Module, C1 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 9468 Body Control Module: Diagrams Body Control Module (BCM) C2 Body Control Module, C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 9469 Body Control Module, C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 9470 Body Control Module: Diagrams Body Control Module (BCM) C3 Body Control Module, C3 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Body Control Module (BCM) C1 > Page 9471 Body Control Module, C3 Part 2 Body Control Module, C3 Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Diagrams > Page 9472 Body Control Module: Description and Operation BODY CONTROL MODULE (BCM) The CTD system is an internal function of the Body Control Module (BCM) which utilizes class 2 serial data and various switch input information to perform CTD functions. When the BCM detects an unauthorized entry, it activates the horns and exterior lamps. The BCM has five basic modes (disarmed, standby, delayed, armed, and alarm) for operating the CTD system. The different modes are described below. 1. The BCM has the CTD system in a disarmed mode until the following conditions are detected: - Ignition key turned to the OFF position. - Any door open. - Doors locked by either the power door lock switch or the LOCK button on the transmitter. 2. The BCM enters the standby mode when the above conditions are detected. In standby mode, the BCM commands the SECURITY indicator to flash. If all the doors are closed and the LOCK button on the transmitter is used, the BCM enters the delayed mode. 3. When the last door is closed, the BCM enters the delayed mode for 30 seconds. In delayed mode the BCM commands the SECURITY indicator to illuminate ON steady. 4. After 30 seconds, the BCM enters the armed mode. Any forced entry activates the alarm mode. 5. When the BCM detects a forced entry, the BCM enters the alarm mode. The BCM activates the horns and exterior lamps for 2 minutes. This is followed by a three minute time-out with the horn no longer active. If no new intrusions are detected after the time-out, the horn is not active.The system must be disarmed or the intrusion condition removed after the time-out for the system to exit alarm mode. The body control module (BCM) contains the theft deterrent system logic. The BCM reads the Passlock(TM) data from the Passlock(TM) sensor. If the Passlock(TM) data is correct, the BCM will send a class 2 message to the PCM to enable the fuel injectors and crank relay. During the tamper mode the vehicle may start. The vehicle will then stall. If the BCM receives the wrong Passlock(TM) data, the VTD system will immediately go into the tamper mode. The tamper mode will lock-out the vehicle fuel injectors and crank relay for 10 minutes. The SECURITY indicator will flash while the VTD is in the tamper mode. If the Passlock(TM) sensor sends a correct password to the BCM when the ignition is in the ON position, the BCM will send a fuel enable and crank relay enable signal to the PCM. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures Body Control Module: Procedures BODY CONTROL MODULE (BCM) PROGRAMMING/RPO CONFIGURATION INTRODUCTION During body control module (BCM) related service, the procedures below are designated to set-up the BCM correctly. Before you start, read these procedures carefully and completely. SETUP NEW BODY CONTROL MODULE (BCM) IMPORTANT: The BCM will not function properly if the Setup New BCM procedure is not performed. - Make sure the battery is fully charged before performing the setup procedure. - Make sure all disconnected devices and connectors have been reconnected - Perform the Theft Deterrent Re-learn procedure after successfully finishing the Setup New BCM procedure. Refer to Programming Theft Deterrent System Components in Theft Deterrent. If the Theft Deterrent Re-learn procedure is not performed after a BCM replacement, the following conditions may occur: The vehicle will not be protected against theft by the PASSLOCK system. - The engine will not crank nor start. 1. Connect a scan tool to the data link connector (DLC). 2. Turn the ignition switch ON. 3. Select Diagnostics and input all of the required data when prompted by the scan tool. 4. Select BODY CONTROL MODULE. 5. Select SPECIAL FUNCTIONS. 6. Select New VIN and input all required data. 7. Exit back to the SPECIAL FUNCTIONS menu. 8. Select BCM REPROGRAMMING. 9. The scan tool will display DO YOU WANT TO SETUP A BODY CONTROL MODULE? At the prompt, select SETUP BCM hotspot on the scan tool. 10. The scan tool will display: NOW SETTING UP THE NEW BODY CONTROL MODULE. 11. When the BCM has been setup successfully, the scan tool will display: BODY CONTROL MODULE SETUP IS COMPLETE. 12. Exit back to the SPECIAL FUNCTIONS menu. 13. Select Point of Sale in this menu. 14. Input all of the required data when prompted by the scan tool. 15. Exit back to the SET OPTIONS menu. 16. Select Option Configuration. 17. Input all of the required data when prompted by the scan tool. 18. When the BCM, VIN, Point of Sale and Option Configuration have been entered, proceed with the Theft Deterrent Re-learn procedure. 19. If the scan tool displays UNABLE TO PROGRAM BCM. BCM IS SECURED, then the BCM must be replaced and this procedure must be repeated on a new BCM. NOTE: After the above procedure has been completed, personalization of the BCM defaults to a default setting. Inform the customer that the personalization settings must be set again. IMPORTANT: After programming, perform the following to avoid future misdiagnosis: 1. Turn the ignition OFF for 10 seconds. 2. Connect the scan tool to the data link connector. 3. Turn the ignition ON with the engine OFF. 4. Use the scan tool in order to retrieve history DTCs from all modules. 5. Clear all history DTCs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information > Service and Repair > Procedures > Page 9475 Body Control Module: Removal and Replacement BODY CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE IMPORTANT: You must perform the new body control module (BCM) setup when replacing the BCM. Refer to Body Control Module (BCM) Programming/RPO Configuration. 1. Disconnect the battery ground (negative) cable. 2. Remove the left instrument panel insulator. 3. Disconnect the BCM electrical connectors (2,3,4). 4. Remove the BCM (1). INSTALLATION PROCEDURE 1. Install the body control module (BCM) (1). 2. Connect the BCM electrical connectors (2,3,4). 3. Install the left instrument panel insulator. 4. Connect the battery ground (negative) cable. 5. Perform the new BCM setup. Refer to Body Control Module (BCM) Programming/RPO Configuration. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Front Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement Front Bumper Cover / Fascia: Service and Repair Fascia Grille Replacement Fascia Grille Replacement Tool Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Remove the upper radiator air baffle. 3. Using J 38778 remove the push-in retainers from the upper grille. 4. Remove the circle retainers from the ends of the grille. 5. Pull forward and up to release the grille retainers. Remove the grille from the front bumper fascia. Installation Procedure 1. Align the lower retainer tabs of the grille to the front bumper fascia. 2. Install the lower grille to the front bumper fascia by pressing down until the tabs are fully seated. 3. Align the outer location pins by manipulating the front bumper fascia and pressing in the grille until fully seated. 4. Install the circle retainers to the ends of the grille. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9484 5. Install the push-in retainers to the upper grille. 6. Install the upper radiator air baffle. 7. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9485 Front Bumper Cover / Fascia: Service and Repair Fascia Extension Replacement - Front Fascia Extension Replacement - Front Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drill out the plastic rivits from the front bumper fascia extension corner to the front fender liner. 3. Remove the lower fascia support. 4. Remove the front fender liner to front bumper fascia screws. 5. Remove the spring clips from the fascia extension. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9486 6. Remove the fascia extension. Installation Procedure 1. Position the fascia extension to the fascia. 2. Install the spring clips starting at the center of the fascia extension and working outward. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screws to the front fender liner at the front of the front bumper fascia. Tighten the front fender liner to fascia screws to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9487 4. Using new plastic rivits, install the 2 plastic rivits to the front bumper fascia extension corner and front fender liner. 5. Install the lower fascia support. 6. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9488 Front Bumper Cover / Fascia: Service and Repair Fascia Reinforcement - Front Bumper Outer (Impala) Fascia Reinforcement - Front Bumper Outer (Impala) Removal Procedure 1. Remove the front bumper fascia. 2. Drill out the 2 rivets from the front bumper fascia reinforcement outer. 3. Remove the front bumper fascia reinforcement outer. Installation Procedure 1. Align the front bumper fascia reinforcement outer to the front bumper fascia. 2. Install the front bumper fascia reinforcement outer to the front bumper fascia using two new rivets. 3. Install the front bumper fascia. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9489 Front Bumper Cover / Fascia: Service and Repair Fascia Replacement - Front Bumper (Impala) Fascia Replacement - Front Bumper (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the front fender liners. 2. Remove the headlamps. 3. Remove the fog lamps, if equipped. 4. Remove the nuts from the front bumper fascia at the fender. 5. Remove the push-in retainers from the upper front bumper fascia support using J 38778. 6. Remove the screws from the front bumper fascia at the lower support. 7. Remove the front bumper fascia from the vehicle. 8. Remove the grille from the front bumper fascia. 9. Remove the front bumper fascia outer support. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9490 1. Install the front bumper fascia outer support. 2. Install the grille. 3. Install the fascia to the vehicle. 4. Install the push-in retainers to the front upper bumper fascia support. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the front bumper fascia to lower support bolts. Tighten the front bumper fascia lower support screws to 2 N.m (18 lb in). 6. Install the front bumper fascia to fender nuts. Tighten the front bumper fascia nuts to 6 N.m (53 lb in). 7. Install the front fender liners. 8. Install the fog lamps, if equipped. 9. Install the headlamps. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9491 Front Bumper Cover / Fascia: Service and Repair Fascia Grille Replacement Fascia Grille Replacement Tool Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Remove the upper radiator air baffle. 3. Using J 38778 remove the push-in retainers from the upper grille. 4. Remove the circle retainers from the ends of the grille. 5. Pull forward and up to release the grille retainers. Remove the grille from the front bumper fascia. Installation Procedure 1. Align the lower retainer tabs of the grille to the front bumper fascia. 2. Install the lower grille to the front bumper fascia by pressing down until the tabs are fully seated. 3. Align the outer location pins by manipulating the front bumper fascia and pressing in the grille until fully seated. 4. Install the circle retainers to the ends of the grille. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9492 5. Install the push-in retainers to the upper grille. 6. Install the upper radiator air baffle. 7. Close the hood. Fascia Extension Replacement - Front Fascia Extension Replacement - Front Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Drill out the plastic rivits from the front bumper fascia extension corner to the front fender liner. 3. Remove the lower fascia support. 4. Remove the front fender liner to front bumper fascia screws. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9493 5. Remove the spring clips from the fascia extension. 6. Remove the fascia extension. Installation Procedure 1. Position the fascia extension to the fascia. 2. Install the spring clips starting at the center of the fascia extension and working outward. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9494 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screws to the front fender liner at the front of the front bumper fascia. Tighten the front fender liner to fascia screws to 2 N.m (18 lb in). 4. Using new plastic rivits, install the 2 plastic rivits to the front bumper fascia extension corner and front fender liner. 5. Install the lower fascia support. 6. Lower the vehicle. Fascia Reinforcement - Front Bumper Outer (Impala) Fascia Reinforcement - Front Bumper Outer (Impala) Removal Procedure 1. Remove the front bumper fascia. 2. Drill out the 2 rivets from the front bumper fascia reinforcement outer. 3. Remove the front bumper fascia reinforcement outer. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9495 1. Align the front bumper fascia reinforcement outer to the front bumper fascia. 2. Install the front bumper fascia reinforcement outer to the front bumper fascia using two new rivets. 3. Install the front bumper fascia. Fascia Replacement - Front Bumper (Impala) Fascia Replacement - Front Bumper (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the front fender liners. 2. Remove the headlamps. 3. Remove the fog lamps, if equipped. 4. Remove the nuts from the front bumper fascia at the fender. 5. Remove the push-in retainers from the upper front bumper fascia support using J 38778. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9496 6. Remove the screws from the front bumper fascia at the lower support. 7. Remove the front bumper fascia from the vehicle. 8. Remove the grille from the front bumper fascia. 9. Remove the front bumper fascia outer support. Installation Procedure 1. Install the front bumper fascia outer support. 2. Install the grille. 3. Install the fascia to the vehicle. 4. Install the push-in retainers to the front upper bumper fascia support. Notice: Refer to Fastener Notice in Service Precautions. 5. Install the front bumper fascia to lower support bolts. Tighten the front bumper fascia lower support screws to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9497 6. Install the front bumper fascia to fender nuts. Tighten the front bumper fascia nuts to 6 N.m (53 lb in). 7. Install the front fender liners. 8. Install the fog lamps, if equipped. 9. Install the headlamps. Fascia Support Bracket Replacement - Front Upper Fascia Support Bracket Replacement - Front Upper Removal Procedure 1. Open the hood. 2. Remove the upper radiator air baffle. 3. Remove the bolts from the center support bracket at the front bumper fascia. 4. Remove the center support bracket from the hood latch center support. Installation Procedure 1. Align the center support bracket to the hood latch center support and to the upper support. 2. Install the bolts to the hood latch center support and hand tighten. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9498 3. Install the bolt to the front bumper fascia upper support. 1. Tighten the bolt to the front bumper fascia upper support to 10 N.m (89 lb in). 2. Tighten the bolts to the hood latch center support to 10 N.m (89 lb in). 4. Install the upper radiator air baffle. 5. Close the hood. Fascia Support Replacement - Front Bumper Lower (Impala) Fascia Support Replacement - Front Bumper Lower (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the screws from the lower front bumper fascia. 2. Remove the push-in retainers from the front bumper fascia lower support at the front bumper impact bar using J 38778. 3. Remove the front bumper fascia lower support from the front bumper fascia and front bumper impact bar. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9499 1. Install the front bumper fascia lower support to the front bumper impact bar. 2. Install the push-in the retainers to the front bumper fascia lower support at the front of the bumper impact bar. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screws to the lower front bumper fascia. Tighten the screws to the lower front bumper fascia to 2 N.m (18 lb in). Fascia Support Replacement - Front Bumper Upper (Impala) Fascia Support Replacement - Front Bumper Upper (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Remove the headlamps. 3. Remove the push-in retainers from the front bumper fascia upper support using J 38778. 4. Remove the front bumper fascia upper support bolts. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9500 5. Remove the front bolt from the front bumper fascia upper support to the hood latch support bracket. 6. Remove the front bumper fascia upper support from the front bumper fascia. Installation Procedure 1. Install the front bumper fascia upper support to the front bumper fascia. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front bumper fascia upper support bolts. Tighten the front bumper fascia upper support bolts to 10 N.m (89 lb in). 3. Install the front bumper fascia upper support to hood latch support bracket bolt. Tighten the hood latch support bracket bolts to 10 N.m (89 lb in). 4. Install the center support bracket bolt. Tighten the center support bracket bolt to 10 N.m (89 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Service and Repair > Fascia Grille Replacement > Page 9501 5. Install the push-in retainers to the front bumper fascia upper support. 6. Install the headlamps. 7. Check the headlamp aim; if a new headlamp was installed, or if service or repairs in the front end area may have disturbed the headlamp mounting brackets. Refer to Headlamp Aiming (Impala) Headlamp Aiming (Monte Carlo). 8. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Front Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Page 9506 Front Bumper Reinforcement: Service and Repair Impact Bar Replacement - Front Bumper (Impala) Removal Procedure 1. Remove the front bumper fascia. 2. Remove the front bumper energy absorber. 3. Remove the wiring harness from the rear of front bumper impact bar. 4. Remove the front bumper impact bar bolts. 5. Remove the front bumper impact bar. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Reinforcement > System Information > Technical Service Bulletins > Page 9507 1. Install the front bumper impact bar to the body. Notice: Refer to Fastener Notice in Service Precautions. Important: The upper right hand location is a net hole locator and must be installed first. 2. Install the front bumper impact bar bolts. Tighten the front bumper impact bar bolts to 25 N.m (18 lb ft). 3. Install the wiring harness to the rear of the front bumper impact bar. 4. Install the front bumper energy absorber. 5. Install the front bumper fascia. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Shock Absorber > System Information > Service and Repair Front Bumper Shock Absorber: Service and Repair Energy Absorber Replacement - Front (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the front bumper fascia. 2. Use J 38778 to remove the push-in retainers from the front bumper energy absorber. 3. Remove the front bumper energy absorber from the front bumper impact bar. Installation Procedure 1. Install the front bumper energy absorber to the front bumper impact bar. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Shock Absorber > System Information > Service and Repair > Page 9511 2. Install the push-in retainers to the front bumper energy absorber. 3. Install the front bumper fascia. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Body - TPO Fascia Cleaning Prior to Painting Rear Bumper Cover / Fascia: Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Fascia Extension Replacement - Rear Rear Bumper Cover / Fascia: Service and Repair Fascia Extension Replacement - Rear Fascia Extension Replacement - Rear Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the rear tires and wheels. 3. Drill out the plastic rivet from the rear fascia extension corner to the splash shield. 4. Remove the rear bumper fascia extension screw from the rear fascia extension corner to the splash shield. 5. Remove the rear bumper fascia extension lower screw from the lower rear fascia to splash shield. 6. Drill out the rivets from the lower rear end of the rear fascia extension. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Fascia Extension Replacement - Rear > Page 9519 7. Remove the spring clips from the fascia extension. 8. Remove the fascia extension. Installation Procedure 1. Install the fascia extension onto the fascia. 2. Install the spring clips through the tabs in the fascia extension. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Fascia Extension Replacement - Rear > Page 9520 3. Using new plastic rivets, install the plastic rivets to the lower rear end of the rear fascia extension. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the rear bumper fascia extension lower screw to the lower rear fascia and splash shield. Tighten the rear bumper fascia extension lower screw to 2 N.m (18 lb in). 5. Using a new plastic rivet, install the plastic rivet to the rear fascia extension corner to the splash shield. 6. Install the rear bumper fascia extension screw to the rear fascia extension corner to the splash shield. Tighten the rear bumper fascia extension screw to 2 N.m (18 lb in). 7. Install the rear wheels and tires. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Fascia Extension Replacement - Rear > Page 9521 Rear Bumper Cover / Fascia: Service and Repair Fascia Replacement - Rear Bumper (Impala) Fascia Replacement - Rear Bumper (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the license plate lamp. 2. Pull back the rear compartment trim panel. Refer to Compartment Trim Panel Replacement - Rear in Body Rear End. 3. Remove the nuts from the rear bumper fascia outer retainers. 4. Remove the bolts in the rear compartment from the rear bumper fascia outer retainers. 5. Remove the rear bumper fascia splash shield. 6. Remove the bolts from the rear bumper fascia outer retainers. 7. Remove the push-in retainers from the rear bumper fascia at the rear impact bar, using the J 38778. 8. Remove the rear bumper fascia from the vehicle. Installation Procedure 1. Position the rear bumper fascia to the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Fascia Extension Replacement - Rear > Page 9522 2. Install the push-in retainers to the rear bumper fascia. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the nuts to the rear bumper fascia outer retainers. Tighten the rear bumper fascia outer retainer nuts to 6 N.m (53 lb in). 4. Install the bolts to the rear bumper fascia outer retainers. Tighten the rear bumper fascia outer retainer bolts to 6 N.m (53 lb in). 5. Install the nut to the rear bumper fascia outer retainer. Tighten the rear bumper fascia outer retainer nut to 6 N.m (53 lb in). 6. Install the rear bumper fascia splash shield. 7. Pull back the rear compartment trim panel. Refer to Compartment Trim Panel Replacement - Rear in Body Rear End. 8. Install the license plate lamp. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Fascia Extension Replacement - Rear > Page 9523 Rear Bumper Cover / Fascia: Service and Repair Fascia Support Replacement - Rear Bumper Outer (Impala) Fascia Support Replacement - Rear Bumper Outer (Impala) Tools Required J 38778 Door Trim Pad Clip Removal Removal Procedure 1. Remove the rear bumper fascia. 2. Remove the rear bumper fascia reinforcement outer push-in retainers using J 38778. 3. Remove the rear bumper fascia reinforcement outer from the rear bumper fascia. Installation Procedure 1. Install the rear bumper fascia reinforcement outer to the rear bumper fascia. 2. Install the rear bumper fascia reinforcement outer push-in retainers. 3. Install the rear bumper fascia. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Fascia Extension Replacement - Rear > Page 9524 Rear Bumper Cover / Fascia: Service and Repair Splash Shield Replacement - Rear Bumper Fascia Splash Shield Replacement - Rear Bumper Fascia Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Drill out the plastic rivit from the rear fascia extension corner if equipped. 2. Remove the rear bumper fascia extension screw if equipped. 3. Remove the rear bumper fascia splash shield nuts. 4. Remove the rear bumper fascia splash shield bolt. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Fascia Extension Replacement - Rear > Page 9525 5. Remove the rear bumper fascia push-in retainer using J 38778. 6. Remove the rear bumper fascia splash shield screws. 7. Remove the rear bumper fascia splash shield. Installation Procedure 1. Install the rear bumper fascia splash shield over the studs. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear bumper fascia splash shield nuts. Tighten the rear bumper fascia splash shield nuts to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Fascia Extension Replacement - Rear > Page 9526 3. Install the rear bumper fascia splash shield bolt. Tighten the rear bumper fascia splash shield bolts to 2 N.m (18 lb in). 4. Install the rear bumper fascia splash shield screws. Tighten the rear bumper fascia splash shield nut to 2 N.m (18 lb in). 5. Install the rear bumper fascia splash shield push-in retainers. 6. Using a new plastic rivit,install the plastic rivit to the rear fascia extension corner to splash shield if equipped. 7. Install the rear bumper fascia extension screw to the rear fascia extension corner to splash shield if equipped. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Service and Repair > Fascia Extension Replacement - Rear > Page 9527 Tighten the rear bumper fascia extension screw to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Body - Polypropylene Energy Absorber Replacement Rear Bumper Reinforcement: Technical Service Bulletins Body - Polypropylene Energy Absorber Replacement Bulletin No.: 07-08-63-001 Date: April 17, 2007 INFORMATION Subject: Information on Repair of Polypropylene Energy Absorbers Models: 2007 and Prior GM Passenger Cars and Trucks (including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X Supercede: This bulletin is being revised to change the repair information. Please discard Corporate Bulletin Number 63-20-02 (Section 8 - Body and Accessories). Because the energy absorbers are relatively low in cost to replace, it is now more cost efficient to replace the energy absorbers whenever they are damaged. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Page 9532 Rear Bumper Reinforcement: Service and Repair Impact Bar Replacement - Rear Bumper (Impala) Removal Procedure 1. Remove the rear bumper fascia. 2. Remove the rear bumper energy absorber. 3. Remove the rear bumper impact bar bolts. 4. Remove the rear bumper impact bar. Installation Procedure 1. Install the rear bumper impact bar to the body. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Reinforcement > System Information > Technical Service Bulletins > Page 9533 Notice: Refer to Fastener Notice in Service Precautions. Important: The lower outboard location is a 4-way net hole locator and must be installed first. 2. Install the rear bumper impact bar bolts. Tighten the rear bumper impact bar bolts to 25 N.m (18 lb ft). 3. Install the rear bumper energy absorber. 4. Install the rear bumper fascia. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Shock Absorber > System Information > Service and Repair Rear Bumper Shock Absorber: Service and Repair Energy Absorber Replacement - Rear (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the rear bumper fascia. 2. Remove the push-in retainers from the rear bumper energy absorber using J 38778. 3. Remove the rear bumper energy absorber from the rear bumper impact bar. Installation Procedure 1. Position the rear bumper energy absorber to the rear bumper impact bar. 2. Install the push-in retainers to the rear bumper energy absorber. 3. Install the rear bumper fascia. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Duct > Component Information > Service and Repair Cabin Ventilation Duct: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Open the rear compartment. 2. Remove the rear bumper fascia. 3. Pull back the rear compartment trim panel. 4. Apply pressure at 2 upper locations and 2 lower locations, using a small, flat-bladed tool in order to release the retainers on the pressure relief valve. 5. Remove the pressure relief valve from the lower quarter panel. Installation Procedure 1. Install the pressure relief valve to the lower quarter panel. 2. Press the pressure relief valve into the quarter lower panel until the retainers lock into place at the upper and lower locations. 3. Pull back the rear compartment trim panel. 4. Install the rear bumper fascia. 5. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Cabin Ventilation Grille > Component Information > Service and Repair Cabin Ventilation Grille: Service and Repair Pressure Relief Valve Replacement Removal Procedure 1. Open the rear compartment. 2. Remove the rear bumper fascia. 3. Pull back the rear compartment trim panel. 4. Apply pressure at 2 upper locations and 2 lower locations, using a small, flat-bladed tool in order to release the retainers on the pressure relief valve. 5. Remove the pressure relief valve from the lower quarter panel. Installation Procedure 1. Install the pressure relief valve to the lower quarter panel. 2. Press the pressure relief valve into the quarter lower panel until the retainers lock into place at the upper and lower locations. 3. Pull back the rear compartment trim panel. 4. Install the rear bumper fascia. 5. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Tools Required J 38778Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Remove the wiper arms. 3. Disconnect the windshield wiper washer hose from the air inlet grille. 4. Use the J 38778 to remove the push-in retainers from the air inlet grille. 5. Remove the air inlet grille from the vehicle. Installation Procedure 1. Install the air inlet grille to the vehicle. 2. Install the push-in retainers to the air inlet grille. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 9547 3. Install the windshield wiper washer hose to the air inlet grille. 4. Install the wiper arms. 5. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair Front Door Exterior Handle: Service and Repair Door Handle Replacement - Front Outside (Impala) Removal Procedure Important: The outside handles have adjustable lock rod. This allows for adjustment of the amount of travel needed to operate the outside handle. When servicing a vehicle with adjustable outside handle-to-lock rods, it is important that all free play between the outside handle and the lock be removed. Do not operate the outside handle before these adjustments are made. Before removing the door handle, apply a double layer of masking tape around the perimeter of the painted surfaces. 1. Position the window completely up. 2. Remove the front door trim panel. 3. Remove the front door water deflector. 4. Remove the front door rear window channel bolt. 5. Remove the front door rear window channel from the front door slot by pulling downward to disengage the retainer clip. 6. Remove the outside door handle rod-to-lock clip from the lock. 7. Remove the front door outside handle lock cylinder. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 9555 8. Remove the hole plug to access to one of the two bolts that attach the outer door handle. 9. Remove the front door outside door handle from the door. 10. Remove the front door outside door handle rod from the handle. Installation Procedure 1. Install the lockcylinder retainer clip to door handle. 2. Install the front door handle rod to the door handle. 3. Install the front outside door handle to the door. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the front door outside door handle bolts. Tighten the front door outside door handle bolts to 10 N.m (89 lb in). 5. Install the front door outside handle lockcylinder. 6. Install a NEW outside handle rod-to-lock clip onto the door lock lever. * Position the outside door handle rod in the clip to eliminate any free play in the outside door handle. * Install the clip cover over the threaded outside door handle rod. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Exterior Handle > System Information > Service and Repair > Page 9556 7. Install the front door rear window channel to the front door, ensuring that the up clip is engaged to the upper channel. 8. Install the front door rear window channel bolt. Notice: Refer to Fastener Notice in Service Precautions. Install the front door rear window channel bolt. Tighten the front door rear window channel bolt to 10 N.m (89 lb in). 9. Install the access hole plug. 10. Install the front door water deflector. 11. Install the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement Front Door Interior Handle: Service and Repair Door Handle Replacement Door Handle Replacement - Front Inside (Impala) Removal Procedure 1. Remove the front door trim panel. 2. Remove the front door water deflector from the front inside door handle. 3. Drill out the rivet (2) from the front inside door handle (1) using a 6.35 mm (1/4 in) drill bit. 4. Remove the lock rod and door handle rod from the front inside door handle. 5. Remove the front inside door handle from the front door inner panel. Installation Procedure 1. Install the front inside door handle by inserting the tabs into the rear door inner panel slots. 2. Install the lock rod and the door handle rod to the front inside door handle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement > Page 9561 3. Install the rivet (2) to the front inside door handle. 4. Install the water deflector to the front inside door handle. 5. Install the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement > Page 9562 Front Door Interior Handle: Service and Repair Door Handle Components Front Door Inside Handle Rod Replacement (Impala) Front Door Inside Handle Rod Replacement (Impala) Removal Procedure 1. Remove the front door lock. 2. Remove the front door inside handle rod from the front door lock. Installation Procedure 1. Install the front door inside handle rod to the front door lock. Push in and rotate the rod through the clip in order to secure the rod. 2. Install the front door lock. Handle Bezel Replacement - Inside HANDLE BEZEL REPLACEMENT - INSIDE (IMPALA) REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement > Page 9563 1. Remove the screw from the inside door handle bezel. 2. Pull out on the bezel at the opening by the handle to disconnect the clip. 3. Remove the bezel from the front door trim panel. 4. Remove the door lock switch from the inside door handle bezel. 5. Remove the handle bezel. INSTALLATION PROCEDURE 1. Install the front door lock switch to the inside door handle bezel. 2. Install the bezel to the front door trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw to the inside door handle bezel. Tighten Tighten the screw to 2 N.m (18 lb in). Handle Bezel Replacement - Inside (Impala) Handle Bezel Replacement - Inside (Impala) Removal Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Service and Repair > Door Handle Replacement > Page 9564 1. Remove the screw from the inside door handle bezel. 2. Pull out on the bezel at the opening by the handle to disconnect the clip. 3. Remove the bezel from the front door trim panel. 4. Remove the door lock switch from the inside door handle bezel. 5. Remove the handle bezel. Installation Procedure 1. Install the front door lock switch to the inside door handle bezel. 2. Install the bezel to the front door trim panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw to the inside door handle bezel. Tighten the screw to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair Front Door Hinge: Service and Repair Hinge Replacement - Front Door (Impala) Removal Procedure Important: In order to minimize door realignment, do not remove both door hinges at the same time. Do each door hinge separately, and replace the broken door hinge first. 1. Open the front door. 2. Clean the mounting surfaces of the hinges with a clean rag and mark the front door hinge locations on each surface with a grease pencil or other suitable marker. 3. Support the front door. 4. Remove the bolts from the bodyside front door hinge. 5. Remove the bolts from the doorside front door hinge. 6. Remove the front door hinge from the vehicle. Installation Procedure 1. Position the front door hinge to the aligment marks. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts to the bodyside front door hinge. Tighten the bolts to the bodyside front door hinge to 33 N.m (24 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Hinge > System Information > Service and Repair > Page 9568 3. Install the bolts to the doorside front door hinge. Tighten the bolts to the doorside front door hinge to 33 N.m (24 lb ft). 4. Remove the door support. 5. Inspect the door for proper operation and alignment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair Front Door Latch: Service and Repair Lock Replacement - Front Door (Impala) Removal Procedure 1. Remove the front door trim panel. 2. Remove the front door water deflector. 3. Remove the front door inside handle rods from the front door inside handle. 4. Remove the clip securing the front door inside handle rods to the front door. 5. Remove the outside handle rod-to-lock clip from the lock. 6. Remove the screws (1) securing the lock to the front door. 7. Remove the lock from the front door with the inside handle rods attached to the lock. 8. Disconnect the electrical connectors. 9. Remove the front door inside handle rods from the lock. Installation Procedure 1. Install the front door inside handle rods to the lock. 2. Install the front door lock in the position through the access hole in the front door inner panel. 3. Connect the electrical connectors. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Service and Repair > Page 9572 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the front door lock screws in the proper fastener tightening sequence: top (1), bottom (2), middle (3). Tighten the front door lock screws to 10 N.m (89 lb in). 5. Install a NEW outside handle rod-to-lock clip onto the front door lock lever. 1. Position the front door outside door handle rod in the clip to eliminate any free play in the front door outside door handle. 2. Install the clip cover closed over the threaded front door outside door handle rod. 6. Install the clip to the front door inside handle rods. 7. Install the front door handle rods to the handle. 8. Install the front door water deflector. 9. Install the front door trim panel. 10. Inspect the door lock system for the proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Technical Service Bulletins > Interior - Power Window Switch Removal Precaution Front Door Panel: Technical Service Bulletins Interior - Power Window Switch Removal Precaution Bulletin No.: 04-08-64-007 Date: April 22, 2004 INFORMATION Subject: Proper Removal of Power Window Switch to Avoid Damage to Door Trim Pad or Power Window Switch - Remove Trim Pad First Models: 2004 Chevrolet Malibu Maxx To replace the left front door power window switch, the door panel must be removed. There is a retaining clip at the front of the switch and two retaining tabs on the side of the switch. The clip and tabs must be released from the back side of the door panel. Trying to pry the switch out of the door trim panel without releasing the tabs and clip from the back will result in damage to either the door trim panel, the switch bezel or both. may result. When removing the door trim panel, be careful not to pull on the wire to the trunk release switch, or damage to the switch. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Pull Cup Replacement Front Door Panel: Service and Repair Armrest Pull Cup Replacement Armrest Pull Cup Replacement (Impala) Removal Procedure 1. Remove the screws from the front and/or rear door armrest pull cup Notice: Apply protective coating/tape at the insertion point of the small flat-bladed tool in order to prevent damage to the inner door trim panel. 2. Remove the front and/or rear door armrest pull cup from the inner door trim panel using a small flat-bladed tool at the front of the front and/or rear door armrest pull cup and press rearward in order to release the clip retainer. 3. Remove the front and/or rear door armrest pull cup from the front and/or rear inner door trim panel. 4. Remove the front door power mirror switch from the front door armrest pull cup. 5. Remove the front and/or rear door power window switch from the front and/or rear door armrest pull cup. * For the front door refer to Power Window Switch Replacement (Impala) Power Window Switch Replacement (Monte Carlo). * For the rear door refer to Power Window Switch Replacement - Rear Door (Impala). Installation Procedure 1. Install the front door power mirror switch to the front door armrest pull cup. 2. Install the front and/or rear door armrest power window switch to the front and/or rear door armrest pull cup. * For the front door refer to Power Window Switch Replacement (Impala) Power Window Switch Replacement (Monte Carlo). * For the rear door refer to Power Window Switch Replacement - Rear Door (Impala). 3. Install the front and/or rear door armrest pull cup to the front and/or rear inner door trim panel pressing into place until fully seated. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the front and/or rear door armrest pull cup Tighten the screws to the front and/or rear door armrest pull cup to 6 N.m (53 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Pull Cup Replacement > Page 9579 Front Door Panel: Service and Repair Bezel Replacement Handle Bezel Replacement - Inside HANDLE BEZEL REPLACEMENT - INSIDE (IMPALA) REMOVAL PROCEDURE 1. Remove the screw from the inside door handle bezel. 2. Pull out on the bezel at the opening by the handle to disconnect the clip. 3. Remove the bezel from the front door trim panel. 4. Remove the door lock switch from the inside door handle bezel. 5. Remove the handle bezel. INSTALLATION PROCEDURE 1. Install the front door lock switch to the inside door handle bezel. 2. Install the bezel to the front door trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screw to the inside door handle bezel. Tighten Tighten the screw to 2 N.m (18 lb in). Handle Bezel Replacement - Inside (Impala) Handle Bezel Replacement - Inside (Impala) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Pull Cup Replacement > Page 9580 Removal Procedure 1. Remove the screw from the inside door handle bezel. 2. Pull out on the bezel at the opening by the handle to disconnect the clip. 3. Remove the bezel from the front door trim panel. 4. Remove the door lock switch from the inside door handle bezel. 5. Remove the handle bezel. Installation Procedure 1. Install the front door lock switch to the inside door handle bezel. 2. Install the bezel to the front door trim panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw to the inside door handle bezel. Tighten the screw to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Pull Cup Replacement > Page 9581 Front Door Panel: Service and Repair Panel Replacement Trim Panel Replacement - Side Front Door TRIM PANEL REPLACEMENT - SIDE FRONT DOOR (IMPALA) TOOLS REQUIRED J 38778 Door Trim Pad Clip Remover REMOVAL PROCEDURE 1. Remove the trim bezel from the front door handle. 2. Remove the front door pull cup. 3. Remove the door trim panel screws from the pull cup support bracket. 4. Disconnect and reposition the electrical connectors. 5. Remove the screw from the upper door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Pull Cup Replacement > Page 9582 6. Remove 2 screws from the door pull handle bracket. 7. Remove the front door trim panel using J 38778 in order to disengage the fasteners from the door inner panel. 8. Remove the upper door trim panel from the front door. INSTALLATION PROCEDURE IMPORTANT: Before installing the front door trim panel to the front door inner panel, the old trim panel retainers MUST be discarded and replaced with NEW trim panel retainers. 1. Install the upper door trim panel to the front door. 2. Install the screw to the upper door trim panel. 3. Install the front door trim panel to the inner door panel. 4. Install 2 screws to the door pull handle bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Pull Cup Replacement > Page 9583 5. Connect and position the electrical connectors to the pull cup. 6. Install the front door pull cup. 7. Install the trim bezel to the front door handle. Trim Panel Replacement - Side Front Door (Impala) Trim Panel Replacement - Side Front Door (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the trim bezel from the front door handle. 2. Remove the front door pull cup. 3. Remove the door trim panel screws from the pull cup support bracket. 4. Disconnect and reposition the electrical connectors. 5. Remove the screw from the upper door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Pull Cup Replacement > Page 9584 6. Remove 2 screws from the door pull handle bracket. 7. Remove the front door trim panel using J 38778 in order to disengage the fasteners from the door inner panel. 8. Remove the upper door trim panel from the front door. Installation Procedure Important: Before installing the front door trim panel to the front door inner panel, the old trim panel retainers MUST be discarded and replaced with NEW trim panel retainers. 1. Install the upper door trim panel to the front door. 2. Install the screw to the upper door trim panel. 3. Install the front door trim panel to the inner door panel. 4. Install 2 screws to the door pull handle bracket. 5. Connect and position the electrical connectors to the pull cup. 6. Install the front door pull cup. 7. Install the trim bezel to the front door handle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Pull Cup Replacement > Page 9585 Front Door Panel: Service and Repair Reflector Replacement - Front Door Warning Reflector Replacement - Front Door Warning Removal Procedure 1. Open the door. 2. Remove the front door trim panel. 3. Grind off the four plastic tabs which were melted to hold the reflector in place. 4. Remove the reflector. Installation Procedure 1. Install the warning reflector on the trim panel by pressing the tabs back into the trim panel. 2. Melt the tabs to secure the reflector to the trim panel. 3. Install the front door trim panel. 4. Close the door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair > Armrest Pull Cup Replacement > Page 9586 Front Door Panel: Service and Repair Water Deflector Replacement - Front Door (Impala) Water Deflector Replacement - Front Door (Impala) Removal Procedure 1. Remove the front door trim panel. 2. Remove the front door pull handle bracket from the front door inner panel. 3. Disconnect all of the required electrical connectors. 4. Remove the inside door handle gasket from. 5. Remove the front door water deflector from the front door inner panel. Installation Procedure 1. Align the front door water deflector to the front door inner panel. Secure the water deflector at the corners. 2. Pull the front door wiring harness leads through the slits in the front door water deflector. 3. Install the front door water deflector, start pressing the adhesive pattern at the bottom center and working outward and upward in order to prevent puckering. 4. Install the inside door handle gasket. 5. Connect all of the required electrical connectors. 6. Install the front door pull handle bracket to the front door inner panel. 7. Install the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments > Lock Striker Adjustment - Door (With Clay or Caulk) Front Door Striker: Adjustments Lock Striker Adjustment - Door (With Clay or Caulk) Lock Striker Adjustment - Door (With Clay or Caulk) Important: Properly algin the door before adjusting the striker. 1. Open the door. 2. Loosen the door striker screws just enough to allow movement of the door striker. 3. Adjust the door striker up or down and inboard or outboard as required. 4. Apply modeling clay or body caulking compound to the door lock opening. Important: Do not close the door all the way. 5. Close the door far enough for the striker to make an impression into the modeling clay or body caulking compound. 6. Open the door and check the door striker impression in the modeling clay or body caulking compound. Notice: Refer to Fastener Notice in Service Precautions. 7. Readjust door striker as required. Add or remove spacers as needed. Tighten the door striker screws to 25 N.m (18 lb ft). 8. Close the door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments > Lock Striker Adjustment - Door (With Clay or Caulk) > Page 9591 Front Door Striker: Adjustments Lock Striker Adjustment - Door (With Mini Wedge) Lock Striker Adjustment - Door (With Mini Wedge) Tools Required J 39346-A Mini Wedge Door Striker Aligner Important: Properly align the door before adjusting the striker. 1. Open the door. 2. Loosen the door striker screws just enough to allow movement of the door striker. 3. Install the J 39346-A. Important: Do not slam the door. 4. Close the door while holding the outside handle in the open position. 5. Open the door. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the door lock striker screws. Tighten the door striker screws to 25 N.m (18 lb ft). 7. Remove the J 39346-A. 8. Close the door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Striker > System Information > Adjustments > Page 9592 Front Door Striker: Service and Repair Striker Anchor Plate Replacement - Door Removal Procedure 1. Remove the front or rear door lock pillar trim to gain access to the anchor plate. 1. Remove the center pillar upper trim panel. 2. Remove the center pillar lower trim panel. 3. Remove the quarter lower trim panel. (Rear Striker). 2. Mark the position of the striker with a grease pencil. 3. Remove the screws from the front door lock striker. 4. Remove the striker and the shims. 5. Remove the anchor plate. Installation Procedure 1. Install the anchor plate. 2. Install the door lock shims and striker. 3. Install the striker screws. 4. Align the door lock striker to the alignment marks. Notice: Refer to Fastener Notice in Service Precautions. 5. Tighten the door lock striker screws. Tighten the striker screws to 25 N.m (18 lb ft). 6. Adjust door lock striker if required. Refer to Lock Striker Adjustment - Door (With Mini Wedge) Lock Striker Adjustment - Door (With Clay or Caulk). 7. Install the front and/or rear trim. 1. Install the center pillar upper trim panel. (Front Striker) 2. Install the center pillar lower trim panel. (Front Striker) 3. Install the quarter lower trim panel. (Rear Striker). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Door Bottom (Impala and Monte Carlo Front) Front Door Weatherstrip: Service and Repair Sealing Strip Replacement - Door Bottom (Impala and Monte Carlo Front) Sealing Strip Replacement - Door Bottom (Impala and Monte Carlo Front) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the front door. 2. Remove the push-in retainers from the front door bottom auxiliary sealing strip using the J 38778. 3. Remove the door bottom auxiliary sealing strip from the front door. Installation Procedure 1. Install the front door bottom auxiliary sealing strip to the front door. 2. Stretch the door bottom auxiliary sealing strip in order to align the push-in retainers to the holes in the front door. 3. Install the push-in retainers to the door bottom auxiliary sealing strip. 4. Close the front door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Door Bottom (Impala and Monte Carlo Front) > Page 9597 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Opening (Impala) Weatherstrip Replacement - Front Door Opening (Impala) Removal Procedure 1. Open the front door. 2. Remove the carpet retainers. 3. Remove the windshield garnish molding. 4. Remove the upper center pillar trim panel. 5. Remove the center lower trim panel. 6. Remove the front door opening weatherstrip by pulling it off the pinch-weld flange. Installation Procedure 1. Position the front door opening weatherstrip to the pinch-weld flange. Starting at the center of the rocker panel area and moving in a clockwise direction press the front door opening weatherstrip to the pinch-weld flange until fully seated. Important: The joint butt ends must have no gap and be located in the center of the of the rocker panel area. 2. Install joint butt ends together. 3. Install the carpet retainers. 4. Install the windshield garnish molding. 5. Install the upper center pillar trim panel. 6. Install the center lower trim panel. 7. Close the front door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Channel Retainer Replacement - Front Door (Impala) Removal Procedure 1. Remove the outside rearview mirror. 2. Pull down the front door window channel in order to gain access to the rivets. 3. Loosen the front door frame applique screws. Refer to Door Frame Applique Replacement - Front (Impala) Door Frame Applique Replacement Front (Monte Carlo). 4. Drill out the rivets. 5. Remove the front door window channel retainer from the front door. Installation Procedure 1. Position the front door window channel retainer to the front door. 2. Install the window channel retainer rivets. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the front door frame applique screws. Refer to Door Frame Applique Replacement Front (Impala) Door Frame Applique Replacement Front (Monte Carlo). 4. Install the front door window channel in position. 5. Install the outside mirror. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 9603 Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Front Door Window (Impala) Removal Procedure 1. Remove the front door trim panel. 2. Remove the front door water deflector. 3. Remove the front door outer belt sealing strip. 4. Remove the front door window. 5. Remove the screws from the front door window channel. 6. Remove the front door window channel from the front door frame. 7. Remove the front door window channel from the front door. 8. Remove the screw from the front door rear window channel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 9604 9. Remove the front door rear window channel from the front door slot by pulling down to disengage the retainer clip. 10. Remove the front door rear window channel from the front door through the access hole in the inner front door panel. Installation Procedure 1. Position the front door window channel front channel into the front door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front door window channel screws. Tighten the front door window channel screws to 10 N.m (89 lb in). 3. Install the front door window channel to the front door starting in the top corner working out in both directions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 9605 Firmly seat the front door window channel to the front door. 4. Install the front door rear window channel to the front door through the access hole in the inner front door panel. 5. Install the front door rear window channel to the front door slot by pushing up to engage the retainer clip. 6. Install the screw to the front door rear window channel. Tighten the front door weatherstrip channel screws to 10 N.m (89 lb in). 7. Install the front door window. 8. Inspect the front door window for proper operation. 9. Install the front door outer belt sealing strip. 10. Install the front door water deflector. 11. Install the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 9606 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Outer (Impala) Removal Procedure 1. Remove the outside rearview mirror. 2. Remove the rear screw from the front door outer belt sealing strip. 3. Remove the front door outer belt sealing strip. Installation Procedure 1. Position the front door outer belt sealing strip to the front door pinch-weld flange. 2. Install the front door outer belt sealing strip to the front door pinch-weld flange pressing into place until fully seated. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw to the rear of the front door outer belt sealing strip. Tighten the outer belt sealing strip screw to 2 N.m (18 lb in). 4. Install the outside rearview mirror. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Window Regulator Replacement - Front Door (Impala) Removal Procedure 1. Position the front door window with a 6.3 mm (1/4 in) space at the top. 2. Tape the window to the window frame. 3. Remove the front door trim panel. 4. Remove the front door water deflector. 5. Disconnect the front window from the front window regulator carrier plate. 6. Disconnect the electrical connector from the front window regulator motor. 7. Loosen the bolts on the front window regulator motor. 8. Loosen the top bolts and remove the lower bolts on the front window regulator rail. 9. Remove the front window regulator, lifting up and out from the key slots on the front door inner panel and through the rear access hole. Installation Procedure 1. Install the top window regulator bolts half way into the window regulator motor and the rail. 2. Position the front window regulator rail through the rear access hole first. 3. Position the front window regulator motor through the rear access hole. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair > Page 9610 4. Install the front window regulator bolts into the key slots. Tighten the front window regulator motor and the rail bolts to 10 N.m (89 lb in). 5. Remove the tape from the front window and position the front window to the front window regulator carrier plate. 6. Connect the front window to the front window regulator carrier plate. 7. Connect the electrical connector to the front window regulator motor. 8. Install the front door water deflector. 9. Install the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair Rear Door Exterior Handle: Service and Repair Door Handle Replacement - Rear Outside Removal Procedure The outside handles have adjustable outside handle-to-lock rods. This allows for adjustment of the amount of effort needed to operate the outside handle. When servicing a vehicle with adjustable outside handle-to-lock rods, it is important that all free play between the outside handle and the lock be removed. Do not operate the outside handle before these connections are made. 1. Remove the rear door trim panel. 2. Remove the rear door water deflector. 3. Unsnap the clip from the outside handle rod and discard the rod-to-lock clip. 4. Remove the rear door outside door handle bolt access plug. 5. Remove the rear door outside door handle bolts (3). 6. Remove the rear door outside door handle with the handle rod from the door. 7. Separate the handle rod from the outside door handle. Installation Procedure 1. Position the rear door outside door handle and the handle rod to the rear door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear door outside door handle bolts (3). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Exterior Handle > System Information > Service and Repair > Page 9616 Tighten the rear door outside door handle bolts to 10 N.m (89 lb in). 3. Install the rear door outside door handle bolt access plug. 4. Install a NEW outside handle rod-to-lock clip onto the door lock lever. 1. Position the outside door handle rod in the clip to eliminate any free play in the outside door handle. 2. Install the clip cover closed over threaded outside door handle rod. 5. Install the rear door water deflector. 6. Install the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Door Handle Replacement - Rear Inside (Impala) Rear Door Interior Handle: Service and Repair Door Handle Replacement - Rear Inside (Impala) Door Handle Replacement - Rear Inside (Impala) Removal Procedure 1. Remove the rear door trim panel. 2. Remove the rear door water deflector from the rear inside door handle. 3. Drill out the rivet (2) from the rear inside door handle using a 6.35 mm (1/4 in) drill bit. 4. Remove the lock rod and door handle rod from the rear inside door handle. 5. Remove the rear inside door handle from the rear door inner panel. Installation Procedure 1. Install the rear inside door handle by inserting the tabs into the rear door inner panel slots. 2. Install the lock rod and the door handle rod to the rear inside door handle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Door Handle Replacement - Rear Inside (Impala) > Page 9621 3. Install the rivet (2) to the rear inside door handle. 4. Install the water deflector to the rear inside door handle. 5. Install the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Door Handle Replacement - Rear Inside (Impala) > Page 9622 Rear Door Interior Handle: Service and Repair Door Handle Rod Replacement - Rear Inside (Impala) Door Handle Rod Replacement - Rear Inside (Impala) Removal Procedure 1. Remove the rear door trim panel. 2. Remove the rear door water deflector. 3. Remove the rear door inside handle rod from the rear door inside door handle (4). 4. Remove the rear door inside handle rod from the retainer clip (4). 5. Remove the rear door inside handle rods from the door lock (6). Installation Procedure 1. Install the inside handle rod to the door lock (6). 2. Push in the rear door handle rod in order to secure it. 3. Install the rear door inside handle to the retainer clip (4). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Handle > Rear Door Interior Handle > System Information > Service and Repair > Door Handle Replacement - Rear Inside (Impala) > Page 9623 4. Install the rear door inside handle rod to the rear door inside door handle. 5. Secure the rear door inside handle rod with a clip. 6. Install the rear door water deflector. 7. Install the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Hinge > System Information > Service and Repair Rear Door Hinge: Service and Repair Hinge Replacement - Rear Door Removal Procedure Important: This procedure is completed with the rear door closed at all times. Do each door hinge separately, and replace the broken door hinge first. 1. Open the front door in order to remove the rear door hinges. 2. Clean the mounting surfaces with clean a rag and mark the rear door hinge locations on each surface with a grease pencil or other suitable marker. 3. Remove the bolts from the doorside rear door hinge. 4. Remove the bolts (1-5) from the bodyside rear door hinge. 5. Remove the rear door hinge from the vehicle. Installation Procedure 1. Position the rear door hinge to the aligment marks. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the bolts (1-5) to the bodyside rear door hinge. Tighten the bodyside rear door hinge bolts to 33 N.m (24 lb ft). 3. Install the bolts to the doorside rear door hinge. Tighten the doorside rear door hinge bolts to 33 N.m (24 lb ft). 4. Close the rear door. 5. Inspect the rear door for proper operation and allignment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair Rear Door Latch: Service and Repair Lock Replacement - Rear Door (Impala) Removal Procedure 1. Remove the rear door trim panel. 2. Remove the rear door water deflector. 3. Remove the rear door outside handle rod from the lock. 4. Remove the rear door inside handle rods at the rear door handle. 5. Remove the clip securing the rear door inside handle rods from the rear door. 6. Remove the rear door lock screws (1). 7. Remove the rear door lock from the rear door with the rear door inside handle rods attached to the lock. 8. Disconnect the electrical connector(s). 9. Remove the rear door inside handle rods from the rear door lock. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Service and Repair > Page 9630 1. Install the rear door inside handle rods to the lock. 2. Install the rear door lock in position through the access hole in the rear door inner panel. 3. Connect the electrical connectors. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the rear door lock screws in the proper fastener tightening sequence as shown in graphic: top (1), bottom (2), middle (3). Tighten the rear door lock screws to 10 N.m (89 lb in). 5. Install a NEW outside handle rod-to-lock clip onto the rear door lock lever. 1. Position the rear door outside door handle rod in the clip to eliminate any free play in the rear door outside door handle. 2. Install the clip cover closed over the threaded rear door outside door handle rods. 6. Install the clip to the rear door inside handle rods. 7. Install the rear door inside handle rods to the rear door inside door handle. 8. Install the rear door water deflector. 9. Install the rear door trim panel. 10. Inspect the lock system for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement Rear Door Panel: Service and Repair Panel Replacement Trim Panel Replacement - Side Rear Door Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the rear door handle trim bezel. 2. Remove the rear door pull cup. 3. Remove the screws from the pull cup bracket. 4. Remove the rear door trim panel using J 38778 to disengage the fasteners from the door inner panel. 5. Disconnect and reposition the electrical connectors. 6. Remove the rear door trim panel from the vehicle. Installation Procedure Important: Before installing the rear door trim panel to the rear door inner panel, the old trim panel retainers MUST be discarded and replaced with NEW trim panel retainers. 1. Install the new trim panel retainers to the rear door trim panel. 2. Connect and route the electrical connectors through the openings in the rear door trim panel. 3. Align the rear door trim panel to the rear door inner panel, guiding the rear door handle through the trim panel. 4. Install the upper edge of the rear door trim panel to the top edge of the inner door panel, pressing down firmly until the retainer clips are fully seated. 5. Align the two locator pins on the rear door trim panel to the front door inner panel. 6. Install the rear door trim panel pressing firmly until the retainer clips are fully seated around the perimeter of the trim panel. Notice: Refer to Fastener Notice in Service Precautions. 7. Install the screws to the pull cup bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 9635 Tighten the screws to the pull cup bracket to 6 N.m (53 lb in). 8. Install the rear door handle trim bezel. 9. Install the rear door switch plate. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 9636 Rear Door Panel: Service and Repair Energy Absorber Pad Replacement Energy Absorber Pad Replacement - Outer Rear Removal Procedure Caution: This vehicle has energy-absorbing foam blocks for side impact protection. To help avoid personal injury in a collision, foam blocks that are damaged, or removed during repairs must be replaced. Failure to replace foam blocks that are removed can violate federal law. 1. Open the rear door. 2. Remove the rear door trim panel. 3. Remove the rear door water deflector. 4. Remove the rear door energy absorber pad screw and clip from the rear door. 5. Grasp the energy absorber with both hands and pull it away from the door. If necessary, warm the outer door panel to soften the adhesive. 6. Use a rag and alcohol to clean the adhesive off the door panel. Installation Procedure 1. Remove the double backed tape protective backing from the rear door outer energy absorber pad. 2. Install the rear door outer energy absorber pad to the rear door. 3. Install the clip and screw to the rear door outer energy absorber pad. 4. Install the rear door water deflector. 5. Install the rear door trim panel. 6. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Panel > System Information > Service and Repair > Panel Replacement > Page 9637 Rear Door Panel: Service and Repair Water Deflector Water Deflector Replacement - Rear Door (Impala) Removal Procedure 1. Remove the rear door trim panel. 2. Remove the rear door pull handle bracket from the rear door inner panel. 3. Disconnect all of the required electrical connectors. 4. Remove the inside door handle gasket. 5. Remove the rear door water deflector from the rear door inner panel. Installation Procedure 1. Align the rear door water deflector to the rear door inner panel. Secure the water deflector at the corners. 2. Pull the rear door wiring harness leads through the slits in the rear door water deflector. 3. Install the rear door water deflector, start pressing the adhesive pattern at the bottom center and working outward and upward in order to prevent puckering. 4. Install the inside door handle gasket. 5. Connect all of the required electrical connectors. 6. Install the rear door pull handle bracket to the rear door inner panel. 7. Install the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments > Lock Striker Adjustment - Door (With Clay or Caulk) Rear Door Striker: Adjustments Lock Striker Adjustment - Door (With Clay or Caulk) Lock Striker Adjustment - Door (With Clay or Caulk) Important: Properly algin the door before adjusting the striker. 1. Open the door. 2. Loosen the door striker screws just enough to allow movement of the door striker. 3. Adjust the door striker up or down and inboard or outboard as required. 4. Apply modeling clay or body caulking compound to the door lock opening. Important: Do not close the door all the way. 5. Close the door far enough for the striker to make an impression into the modeling clay or body caulking compound. 6. Open the door and check the door striker impression in the modeling clay or body caulking compound. Notice: Refer to Fastener Notice in Service Precautions. 7. Readjust door striker as required. Add or remove spacers as needed. Tighten the door striker screws to 25 N.m (18 lb ft). 8. Close the door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Striker > System Information > Adjustments > Lock Striker Adjustment - Door (With Clay or Caulk) > Page 9642 Rear Door Striker: Adjustments Lock Striker Adjustment - Door (With Mini Wedge) Lock Striker Adjustment - Door (With Mini Wedge) Tools Required J 39346-A Mini Wedge Door Striker Aligner Important: Properly align the door before adjusting the striker. 1. Open the door. 2. Loosen the door striker screws just enough to allow movement of the door striker. 3. Install the J 39346-A. Important: Do not slam the door. 4. Close the door while holding the outside handle in the open position. 5. Open the door. Notice: Refer to Fastener Notice in Service Precautions. 6. Tighten the door lock striker screws. Tighten the door striker screws to 25 N.m (18 lb ft). 7. Remove the J 39346-A. 8. Close the door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Opening Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Opening Weatherstrip Replacement - Rear Door Opening Removal Procedure 1. Open the rear door. 2. Remove the trim panels. 3. Remove the weatherstrip from the rear door opening by pulling the weatherstrip off the pinchweld flange. Installation Procedure 1. Position the rear door opening weatherstrip to the pinchweld flange. Starting at the center of the rocker panel area and moving in a clockwise direction, press the weatherstrip to the pinchweld flange until fully seated. Important: The joint butt ends must have no gap and must be located in the center of the of the rocker panel area. 2. Install the joint butt ends together. 3. Install the trim panels. 4. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Opening > Page 9647 Rear Door Weatherstrip: Service and Repair Sealing Strip Replacement - Door Bottom (Impala Rear) Sealing Strip Replacement - Door Bottom (Impala Rear) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the rear door. 2. Remove the push-in retainers from the rear door bottom auxiliary sealing strip using the J 38778. 3. Remove the door bottom auxiliary sealingstrip from the rear door. Installation Procedure 1. Position the door bottom auxiliary weatherstrip to the rear door. 2. Stretch the door bottom auxiliary weatherstrip in order to align the push-in retainers to the holes in the door. 3. Install the push-in retainers to the door bottom auxiliary weatherstrip. 4. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Opening > Page 9648 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Window Weatherstrip Replacement - Rear Door Window (Impala) Removal Procedure 1. Place the rear window in the full down position. 2. Remove the rear door trim panel. 3. Remove the outer belt sealing strip. 4. Remove the rear window channel from the door. Installation Procedure 1. Position the rear window channel to the rear door starting in the corner. Work outward in both directions. 2. Firmly seat the rear window channel to the rear door. 3. Inspect the rear door window for proper operation. 4. Install the outer belt sealing strip. 5. Install the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Opening > Page 9649 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement Sealing Strip Replacement - Rear Door Bottom Auxiliary Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the rear door. 2. Remove the push-in retainers from the rear door bottom auxiliary sealing strip using the J 38778. 3. Remove the door bottom auxiliary sealingstrip from the rear door. Installation Procedure 1. Position the door bottom auxiliary weatherstrip to the rear door. 2. Stretch the door bottom auxiliary weatherstrip in order to align the push-in retainers to the holes in the door. 3. Install the push-in retainers to the door bottom auxiliary weatherstrip. 4. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel Rear Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Channel Retainer Replacement - Rear Door (Impala) Removal Procedure 1. Partially remove the upper portion of the rear door frame appliques. Refer to Door Frame Applique Replacement - Rear (Impala Front) Door Frame Applique Replacement - Rear (Impala Rear). 2. Pull downwards on the rear door window channel to gain access to the rivets. 3. Drill out the rivets. 4. Remove the forward screw to the rear window channel retainer. 5. Remove the rear window channel retainer from the rear door. Installation Procedure 1. Position the rear window weatherstrip retainer. 2. Push downwards on the rear door window channel to gain access to the rivets holes. 3. Install weather strip retainer rivets. 4. Install the rear door frame applique. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 9655 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Rear Door Window (Impala) Removal Procedure 1. Place the rear window in the full down position. 2. Remove the rear door trim panel. 3. Remove the outer belt sealing strip. 4. Remove the rear window channel from the door. Installation Procedure 1. Position the rear window channel to the rear door starting in the corner. Work outward in both directions. 2. Firmly seat the rear window channel to the rear door. 3. Inspect the rear door window for proper operation. 4. Install the outer belt sealing strip. 5. Install the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 9656 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Rear Door Window Belt Outer (Impala) Removal Procedure 1. Position the rear window all the way down. 2. Remove the rear door trim panel to have access to these screws. 3. Remove the rear door outer belt sealing strip screws. 4. Remove the rear window outer belt sealing strip by pulling the sealing strip from the rear door pinch-weld flange. Installation Procedure 1. Position the rear door outer belt sealing strip to the rear door pinch-weld flange. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 9657 2. Install the rear door outer belt sealing strip to the pinch-weld flange, pressing into place until full seated. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the rear door outer belt sealing strip screws. Tighten the rear door outer belt sealing strip screws to 2 N.m (18 lb in). 4. Install Rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair Window Regulator Replacement - Rear Door (Impala) Removal Procedure 1. Position the front door window with a 6.3 mm (1/4 in) space at the top. 2. Tape the window to the window frame. 3. Remove the rear door trim panel. 4. Remove the rear door water deflector. 5. Disconnect the rear window from the rear window regulator carrier plate. 6. Disconnect the electrical connector from the rear window regulator motor. 7. Loosen the bolts on the rear window regulator motor. 8. Loosen the bolts on the rear window regulator rail. 9. Remove the rear window regulator, lifting up and out from the key slots on the rear door inner panel and through the rear access hole. Installation Procedure 1. Install the rear window regulator bolts half way into the rear window regulator motor and the rail. 2. Position the rear window regulator rail through the rear access hole first. 3. Position the rear window regulator motor through the rear access hole. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Window Regulator > System Information > Service and Repair > Page 9661 4. Install the rear window regulator into the key slots. Tighten the rear window regulator motor and the rail bolts to 10 N.m (89 lb in). 5. Remove the tape from the rear window and position the rear window to the rear window regulator carrier plate. 6. Connect the rear window to the rear window regulator carrier plate. 7. Connect the electrical connector to the rear window regulator motor. 8. Install the rear door water deflector. 9. Install the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Filler Door Replacement (Impala) Fuel Door: Service and Repair Fuel Filler Door Replacement (Impala) Fuel Filler Door Replacement (Impala) Removal Procedure 1. Open the fuel filler door. 2. Drill out the rivits from the fuel filler door. 3. Remove the fuel filler door from the quarter panel. Installation Procedure 1. Align the fuel filler door to the holes in the quarter panel. 2. Install the fuel filler door to the quarter panel using new rivits. 3. Close the fuel filler door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Filler Door Replacement (Impala) > Page 9666 Fuel Door: Service and Repair Fuel Filler Pocket Replacement (Impala) Fuel Filler Pocket Replacement (Impala) Removal Procedure 1. Open the fuel filler door. 2. Remove the fuel filler cap. 3. Remove the bolts from the fuel filler pocket at the fuel filler neck. 4. Remove the bolts from the fuel filler pocket. 5. Remove the fuel filler pocket. Installation Procedure 1. Install the fuel filler pocket to the fuel filler neck. 2. Press until the pocket is fully seated. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the fuel filler neck bolts. Tighten the fuel filler neck bolts to 5 N.m (44 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service and Repair > Fuel Filler Door Replacement (Impala) > Page 9667 4. Install the fuel filler pocket bolts. Tighten the fuel filler pocket bolts to 5 N.m (44 lb in). 5. Replace the fuel filler cap. 6. Close the fuel filler door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair Hood Hinge: Service and Repair Hood Hinge Replacement Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Remove the hood. 2. Remove the hood rear side seal. 3. Remove the hood assist rod. 4. Loosen the hood hinge to fender bolts, but do not remove the bolts. 5. Center punch the spot weld. 6. Drill out the spot weld using a 9.5 mm (3/8 in) drill bit. 7. Remove the hood hinge to fender bolts. 8. Remove the hood hinge from the fender. 9. Repair the paint on the fender where the door hinge was removed. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Hinge > Component Information > Service and Repair > Page 9672 1. Align the hood hinge to the fender. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the hood hinge to fender bolts. Tighten the hood hinge to fender bolts to 25 N.m (18 lb ft). 3. Install the hood. 4. Install the hood assist rod. 5. Install the hood rear side seal. 6. Adjust the hood, as required. Refer to Hood Adjustment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Insulator / Pad > Component Information > Service and Repair Hood Insulator / Pad: Service and Repair Hood Insulator Replacement Tools Required J 38778Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Use J 38778 to remove the hood insulator push-in retainers. 3. Remove the hood insulator from the hood. Installation Procedure 1. Install the hood insulator to the hood support brackets. 2. Align the hood insulator retainers holes to the holes in the hood. 3. Install the push-in retainers to the hood. 4. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement Hood Latch: Service and Repair Hood Latch Replacement Hood Latch Replacement Removal Procedure 1. Open the hood. 2. Remove the upper radiator air baffle. 3. Remove the support bracket from the front upper fascia. 4. With a grease pencil, mark the position of the hood latch to the center support bracket. 5. Remove the bolts from the hood latch. Important: Do not crimp the hood release cable. 6. Remove the hood release cable from the hood latch by squeezing the cable retainer. 7. Remove the hood latch from the vehicle. Installation Procedure 1. Install the hood release cable to the hood latch. 2. Align the hood latch to the marks on the center support bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement > Page 9680 Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts that secure the hood latch to the center support. Tighten the bolts to 10 N.m (89 lb in). 4. Install the support bracket to the front upper fascia. 5. Install the upper radiator air baffle. 6. Adjust the hood, if required. Refer to Hood Adjustment. 7. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement > Page 9681 Hood Latch: Service and Repair Hood Latch Support Replacement Hood Latch Support Replacement Removal Procedure 1. Open the hood. 2. Remove the upper radiator air baffle. 3. Remove the hood latch from the hood latch support. 4. Remove the bolts from the upper support bracket to the front bumper fascia. 5. Remove the bolts from the hood latch support at the upper tie bar. 6. Remove the nut from the hood latch support at the lower tie bar. 7. Remove the hood latch support from the vehicle. Installation Procedure 1. Install the hood latch support to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the hood latch support bolts to the upper tie bar. Tighten the bolts to 25 N.m (18 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch > Component Information > Service and Repair > Hood Latch Replacement > Page 9682 3. Install the hood latch support nut to the lower tie bar. Tighten the nut to 10 N.m (89 lb in). 4. Install the bolts to the upper support bracket at the front bumper fascia. 5. Install the hood latch to the hood latch support. 6. Install the upper radiator air baffle. 7. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair Hood Latch Release: Service and Repair Hood Latch Release Handle Replacement Removal Procedure 1. Remove the left instrument panel insulator. 2. Remove the bolts from the hood release handle base. 3. Remove the hood release cable from the hood release handle. 4. Remove the hood release handle from the instrument panel. Installation Procedure 1. Install the hood release cable to the hood release handle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release > Component Information > Service and Repair > Page 9686 2. Install the hood release handle to the instrument panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the bolts to hood release handle base. Tighten the hood release handle bolts to 2 N.m (18 lb in). 4. Install the left instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair Hood Latch Release Cable: Service and Repair Hood Latch Release Cable Replacement Removal Procedure 1. Open the hood. 2. Block the hood latch to prevent the hood locking until the hood release cable has been installed. 3. Disconnect the hood release cable from the hood latch by squeezing the hood release cable retainer. 4. Remove hood release cable from the hood latch bracket. 5. Remove the air cleaner. * For the 3.4 L engine, refer to Air Cleaner Assembly Replacement in Computers and Control Systems. * For the 3.8 L engine, refer to Air Cleaner Assembly Replacement in Computers and Control Systems. 6. Remove the hood release cable retainers from the upper tie bar. 7. Remove the hood release cable retainers from the engine compartment side rail. 8. Remove the hood release cable from the hood release handle. 9. Pull the carpet back to access the hood release cable. Important: Ensure the end of the wire or string remains in the passenger compartment. 10. Tie the wire or string to the end of the hood release cable in order to aid in the installation of the new hood release cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 9690 11. Use a small, flat-bladed tool to remove the grommet from the dash. 12. Remove the hood release cable from the dash. 13. Remove the wire or string from the hood release cable. 14. Remove the hood release cable from the vehicle. Installation Procedure 1. Tie the wire or string to the hood release cable. 2. Install the hood release cable to the vehicle. 3. Pull the hood release cable through the dash until the grommet is seated in the hole. 4. Install the grommet into the dash. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Latch Release Cable > Component Information > Service and Repair > Page 9691 5. Install the hood release cable retainers to the engine compartment side rail. 6. Install the hood release cable retainers to the upper tie bar. 7. Connect the hood release cable to the hood latch. 8. Install the air cleaner. * For the 3.4 L engine, refer to Air Cleaner Assembly Replacement in Computers and Control Systems. * For the 3.8 L engine, refer to Air Cleaner Assembly Replacement in Computers and Control Systems. 9. Install the hood release cable to the hood release handle. 10. Install the carpet back to its original position. 11. Remove the block from the hood latch. 12. Inspect the hood release cable for proper operation before closing the hood. 13. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair Hood Shock / Support: Service and Repair Assist Rod Replacement - Hood Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Open and support the hood. 2. Lift up the retainer clips on the assist rod using a small flat-bladed tool. Notice: Refer to Liftgate/Hood Assist Rod Notice in Service Precautions. 3. Pull the upper end of the assist rod from the ball joint on the hood. 4. Pull the lower end of the assist rod from the ball joint on the lower hood hinge. Installation Procedure 1. Press the upper end of the assist rods on to the ball joint on the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Service and Repair > Page 9695 2. Press the lower end of the assist rods on to the ball joint on the lower hood hinge 3. Remove the support from the hood. 4. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Stop > Component Information > Service and Repair Hood Stop: Service and Repair Hood Bumper Replacement Removal Procedure 1. Raise the hood. 2. Remove the hood bumper (1) from the vehicle by unscrewing the bumper (1) counterclockwise. Installation Procedure 1. Install the hood bumper (1) to the vehicle by screwing the bumper (1) clockwise into the vehicle. 2. Adjust the hood bumper (1) in order to ensure that the hood is flush with the front fender. 3. Lower the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Hood Front Hood Weatherstrip: Service and Repair Seal Replacement - Hood Front Seal Replacement - Hood Front Tools Required J 38778Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Use J 38778 to remove the push-in retainers from the front air seal. 3. Remove the front air seal from the hood. Installation Procedure 1. Install the front air seal to the hood. 2. Install the push-in retainers to the front air seal into the hood. 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Hood Front > Page 9703 Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Seal Replacement - Hood Rear Removal Procedure 1. Open the hood. 2. Pull the hood rear weatherstrip from the pinch-weld flange. 3. Remove the hood rear weatherstrip from the vehicle. Installation Procedure 1. Install the hood rear weatherstrip to the pinch-weld flange. 2. Press the hood rear weatherstrip onto the pinch-weld flange. 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Hood Front > Page 9704 Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Side Seal Replacement - Hood Rear Side Removal Procedure 1. Open the hood. 2. Pull the rear side hood seal from the pinch-weld flange and motor compartment flange. 3. Remove the rear side hood seal from the vehicle. 4. Using 3M(TM) P/N 8984 Adhesive Remover or equivalent, clean any adhesive from the pinch-weld flange and motor compartment flange surface. Installation Procedure 1. Remove the protective backing paper from the adhesive on the rear side hood seal. 2. Install the rear side hood seal to the pinch-weld flange and motor compartment flange. 3. Press the side rear hood seal onto the pinch-weld flange and motor compartment flange until the adhesive is fully adhered. 4. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Hood Front > Page 9705 Hood Weatherstrip: Service and Repair Seal Replacement - Plenum to Hood Seal Replacement - Plenum to Hood Removal Procedure 1. Open the hood. 2. Remove the right side of the air inlet grille. 3. To remove the seal from the pinch-weld flange, start at the passenger side corner of the seal and pull forward and off of the pinch-weld flange. Installation Procedure 1. Align the seal to the pinch-weld flange. 2. Press to install the seal to the pinch-weld flange, start at the passenger side corner and work toward the center of the car. 3. Install the right side of the air inlet grille. 4. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Actuator > Component Information > Diagrams Rear Compartment Lid Release Actuator Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations Inside Rear Compartment Lid Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 9713 Rear Compartment Lid Ajar Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Ajar Switch > Component Information > Service and Repair Trunk / Liftgate Ajar Switch: Service and Repair REAR COMPARTMENT LID AJAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Open the rear compartment. 2. Remove the rear compartment lid latch. 3. Remove the rear compartment lid ajar lamp/switch to rear compartment lid latch screw (5). 4. Remove the compartment lid ajar lamp/switch (6) from the rear compartment lid latch (8). INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Ajar Switch > Component Information > Service and Repair > Page 9717 1. Position the rear compartment lid ajar lamp/switch (6) to the rear compartment lid latch (8). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear compartment lid ajar lamp/switch to rear compartment lid latch screw (5). Tighten Tighten the rear compartment lid ajar lamp/switch to rear compartment lid latch screw to 5 N.m (44 lb in). 3. Install the rear compartment lid latch. 4. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair Trunk / Liftgate Hinge: Service and Repair Hinge Replacement - Rear Compartment Lid Removal Procedure 1. Remove the rear compartment lid. 2. Remove the rear compartment lid struts. 3. Use a grease pencil in order to mark the quarter panel hinge to the quarter panel. 4. Remove the bolts from the rear compartment hinge. 5. Remove the rear compartment hinge from the quarter panel. Installation Procedure 1. Align the rear compartment hinge to the quarter panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear compartment hinge to rear quarter bolts. Tighten the rear compartment hinge to rear quarter bolts to 25 N.m (18 lb ft). 3. Install the rear compartment lid. 4. Install the rear compartment lid struts. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Hinge > Component Information > Service and Repair > Page 9721 5. Adjust the rear compartment lid hinge as required. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Latch > Component Information > Service and Repair Trunk / Liftgate Latch: Service and Repair Latch Replacement - Rear Compartment Lid Removal Procedure 1. Open the rear compartment. 2. Use a grease pencil to mark the location of the rear compartment latch. 3. Disconnect the electrical connectors from the rear compartment latch. 4. Remove the nuts that retain the rear compartment latch. 5. Remove the rear compartment latch from the rear compartment. Installation Procedure 1. Align the rear compartment latch to the marks made on the rear compartment. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear compartment latch nuts. Tighten the rear compartment latch nuts to 9 N.m (80 lb in). 3. Connect the electrical connectors to the rear compartment latch. 4. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Replacement - Rear Compartment Lid (Impala) Removal Procedure 1. Remove the rear compartment lid applique. 2. Drill out the 2 rivets from the rear compartment lock cylinder. 3. Remove the rear compartment lock cylinder and gasket from the rear compartment lid. Installation Procedure 1. Align the lock cylinder shaft to the rear compartment lid latch. 2. Align the rear compartment lock cylinder and gasket to the holes in the rear compartment lid, and press in until fully seated. 3. Install the rear compartment lock cylinder and gasket to the rear compartment lid using 2 rivets. 4. Install the rear compartment lid applique. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair Trunk / Liftgate Shock / Support: Service and Repair Strut Replacement - Rear Compartment Lid Removal Procedure Caution: When a hood hold open device is being removed or installed, provide alternate support to avoid the possibility of damage to the vehicle or personal injury. 1. Open and support the rear compartment. 2. Using a small flat-bladed tool, lift up the retainer at the bottom and the top of the rear compartment strut. Notice: Apply pressure only at the end of the liftgate/hood assist rod that you are removing or attaching. Do NOT apply pressure to the middle of the rod because damage or bending will result. 3. Remove the rear compartment strut from the ball studs on the hinge. 4. Remove rear compartment strut from the vehicle. Installation Procedure 1. Align the top and bottom of the rear compartment strut with the ball studs on the hinge. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Shock / Support > Component Information > Service and Repair > Page 9731 2. Install the rear compartment strut onto the upper ball stud, pressing into place until fully seated. 3. Install the rear compartment strut onto the lower ball stud, pressing into place until fully seated. 4. Close the upper and lower strut retainers. 5. Remove the support and close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Striker > Component Information > Service and Repair Trunk / Liftgate Striker: Service and Repair Lock Striker Replacement - Rear Compartment Lid Removal Procedure 1. Open the rear compartment. 2. Remove the rear compartment sill plate. 3. Pull back the rear compartment trim panel. Refer to Compartment Trim Panel Replacement - Rear. 4. Remove the rear compartment lid lock striker bolt from inside the rear compartment. 5. Remove the rear licence plate in order to access the access hole. 6. Remove the rear compartment lid lock striker bolts through the access hole. 7. Remove the rear compartment lid lock striker. Installation Procedure 1. Align the rear compartment lid lock striker to the rear compartment body panel. 2. Install the rear compartment lid lock striker bolts to the outside and the inside of the vehicle. Install the outside striker bolts through the access hole. Hand tighten the outside and the inside bolts, allowing for the adjustment of the lock striker for the rear compartment lid. Notice: Refer to Fastener Notice in Service Precautions. Important: Because the sealer may squeeze out on the rear compartment lid lock striker bolts, verify the fastener tightening specifications at least twice. 3. Close the rear compartment lid in order to set the adjustment. Tighten the rear compartment lid lock striker outside bolts to 16 N.m (11 lb ft). 4. Open the rear compartment. Tighten the rear compartment lid lock striker inside bolt to 16 N.m (11 lb ft). 5. Install the rear compartment trim. 6. Install the rear compartment sill plate. 7. Close the rear compartment. 8. Install the rear licence plate. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations Lower Left Center Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 9738 Rear Compartment Lid Release Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 9739 Trunk / Liftgate Switch: Service and Repair REAR COMPARTMENT LID SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Release the LH instrument panel (IP) insulator tabs from the lower IP trim pad retainers for access. 2. Remove the LH fuse block access cover. 3. Remove the steering column opening filler panel screws. 4. Release the steering column opening filler panel retainers from the IP lower trim panel. Carefully lower the steering column opening filler panel away from the IP lower trim panel. 5. Disconnect the electrical connector from the rear compartment release switch. 6. Remove the rear compartment release switch. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations > Page 9740 1. Install the rear compartment release switch. 2. Connect the electrical connector to the rear compartment release switch. 3. Align the steering column opening filler panel to the instrument panel (IP) lower trim panel. Install the steering column opening filler panel retainers to the IP lower trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the steering column opening filler panel screws. Tighten Tighten the steering column opening filler panel screws to 2 N.m (18 lb in). 5. Install the LH IP insulator tabs to the lower IP trim pad retainers. 6. Install the LH fuse block access cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Compartment Opening (Impala) Removal Procedure 1. Open the rear compartment. 2. Remove the rear compartment weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the metal joint of the weatherstrip to the center of the rear compartment lid striker. Important: In order to minimize bulging conditions, avoid stretching the weatherstrip around the corners. 2. Install the rear compartment weatherstrip onto the pinch-weld flange, starting at the top center of the lid opening and working toward the bottom center. Use a rubber mallet in order to ensure that the weatherstrip is fully engaged to the pinch-weld flange. 3. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Back Window Glass Moulding / Trim > Component Information > Service and Repair Back Window Glass Moulding / Trim: Service and Repair Rear Window Reveal Molding Replacement The rear window reveal molding is an applied molding design separate from the window. The rear window reveal molding is bonded to the rear window and may be bonded to the body. The rear window reveal molding may be replaced with rear window as an assembly, or the rear window reveal molding may be available as a separate service part. Refer to Urethane Adhesive Installation of Stationary Windows. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Technical Service Bulletins > 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION Body Emblem: Technical Service Bulletins 06-08-111-004B - BULLETIN CANCELLATION NOTIFICATION TECHNICAL Bulletin No.: 06-08-111-004B Date: September 25, 2009 Subject: Information on Discoloration, Blistering, Peeling or Erosion of Various Exterior Emblems Including Chevy Bowtie (Bulletin Cancelled) Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being cancelled. Please discard Corporate Bulletin Number 06-08-111-004A (Section 08 - Body & Accessories). This bulletin is being cancelled. The information is no longer applicable. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Front Bumper Fascia Body Emblem: Service and Repair Emblem Replacement - Front Bumper Fascia Emblem Replacement - Front Bumper Fascia Removal Procedure Tools Required J 25070Heat Gun 1. When replacing or repairing an emblem/nameplate do the following: 1. Use tape to protect the mounting surface during removal. 2. Use tape for alignment marks for installation of the emblem/nameplate. 2. To remove an emblem/nameplate, heat the emblem/nameplate using J 25070. Apply heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 3. Use a plastic, flat-bladed tool to remove the emblem/nameplate from the panel surface. 4. When replacing, remove all adhesive as follows: * For body panels use a 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07501 or equivalent. * For plastic panels use a lint-free cloth and Varnish Makers and Painters (VMP) naptha or a 50/50 mixture by volume of isopropyl alcohol and water to remove the adhesive. Installation Procedure Important: Apply the emblem/nameplate in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. 1. Clean the area where the emblem/nameplate will be installed. Use a lint free cloth and Varnish Makers and Painters (VMP) naptha or a 50/50 mixture by volume of isopropyl alcohol and water to clean the area. 2. Dry the area thoroughly. 3. Apply tape and mark the location as shown. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Front Bumper Fascia > Page 9754 4. Heat the mounting surface to approximately 27-41°C (80-105°F). 5. Ensure that the temperature of the emblem/nameplate is approximately 29-32°C (85-90°F). 6. Remove the protective liner from the back of the emblem/nameplate. 7. Position the emblem/nameplate to the location marks and press the emblem/nameplate to the mounting surface. 8. Apply equal pressure along the emblem/nameplate to uniformly bond the item to the mounting surface. 9. Remove the protective tape from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Front Bumper Fascia > Page 9755 Body Emblem: Service and Repair Emblem/Nameplate Replacement - Door Emblem/Nameplate Replacement - Door Tools Required J 25070 Heat Gun Removal Procedure 1. Apply tape for alignment marks to aid in the installation of the emblem/nameplate. 2. Use the tape to protect the mounting surface during removal. 3. Heat the emblem/nameplate using the J 25070. Apply heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Use a plastic, flat-bladed tool to remove the emblem/nameplate from the panel surface. 5. When replacing a emblem/nameplate, remove all adhesive as follows: * For body panels use a 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07502 or equivalent. * For plastic panels use a lint-free cloth and Varnish Makers and Painters (VMP) naptha or a 50/50 mixture by volume of isopropyl alcohol and water to remove the adhesive. Installation Procedure Important: Apply the emblem/nameplate in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. 1. Ensure the area where the nameplate will be installed is clean and dry. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Front Bumper Fascia > Page 9756 2. Apply tape and mark the location as shown for the left door emblem/nameplate. 3. Apply tape and mark the location as shown for the right door emblem/nameplate. 4. Heat the mounting surface to approximately 27-41°C (80-105°F) using the J 25070, if necessary. 5. Ensure that the temperature of the emblem/nameplate is approximately 29-32°C (85-90°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 6. Remove the protective liner from the back of the nameplate. 7. Position the emblem/nameplate to the location marks and press the emblem/nameplate to the mounting surface. 8. Apply equal pressure along the emblem/nameplate to uniformly bond the item to the mounting surface. 9. Remove the protective tape from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Front Bumper Fascia > Page 9757 Body Emblem: Service and Repair Emblem/Nameplate Replacement - Quarter Panel (Impala) Emblem/Nameplate Replacement - Quarter Panel (Impala) Tools Required J 25070 Heat Gun Removal Procedure 1. Apply tape for alignment marks to aid in the installation of the emblem/nameplate. 2. Use the tape to protect the mounting surface during removal. 3. Heat the emblem/nameplate using the J 25070. Apply heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Use a plastic, flat-bladed tool to remove the emblem/nameplate from the panel surface. 5. When replacing a emblem/nameplate, remove all adhesive as follows: * For body panels use a 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07502 or equivalent. * For plastic panels use a lint-free cloth and Varnish Makers and Painters (VMP) naptha or a 50/50 mixture by volume of isopropyl alcohol and water to remove the adhesive. Installation Procedure Important: Apply the emblem/nameplate in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. 1. Ensure the area where the emblem/nameplate will be installed is clean and dry. 2. Apply tape and mark the location as shown for the left or right side Impala quarter panel emblem/nameplate. 3. Heat the mounting surface to approximately 27-41°C (80-105°F) using the J 25070, if necessary. 4. Ensure that the temperature of the emblem/nameplate is approximately 29-32°C (85-90°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 5. Remove the protective liner from the back of the emblem/nameplate. 6. Position the emblem/name plate to the location marks and press the emblem/nameplate to the mounting surface. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Front Bumper Fascia > Page 9758 7. Apply equal pressure along the emblem/nameplate to uniformly bond the item to the mounting surface. 8. Remove the protective tape from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Front Bumper Fascia > Page 9759 Body Emblem: Service and Repair Emblem/Nameplate Replacement - Rear Compartment Lid (Impala) Emblem/Nameplate Replacement - Rear Compartment Lid (Impala) Tools Required J 25070 Heat Gun Removal Procedure 1. Apply tape for alignment marks to aid in the installation of the emblem/nameplate. 2. Use the tape to protect the mounting surface during removal. 3. Heat the emblem/nameplate using the J 25070. Apply heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Use a plastic, flat-bladed tool to remove the emblem/nameplate from the panel surface. 5. When replacing a emblem/nameplate, remove all adhesive as follows: * For body panels use a 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07502 or equivalent. * For plastic panels use a lint-free cloth and Varnish Makers and Painters (VMP) naptha or a 50/50 mixture by volume of isopropyl alcohol and water to remove the adhesive. Installation Procedure Important: Apply the emblem/nameplate in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. 1. Ensure the area where the emblem/nameplate will be installed is clean and dry. 2. Apply tape and mark the location as shown for the Impala emblem/nameplate. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Body Emblem > Component Information > Service and Repair > Emblem Replacement - Front Bumper Fascia > Page 9760 3. Apply tape and mark the location as shown for the Impala emblem/nameplate. 4. Heat the mounting surface to approximately 27-41°C (80-105°F) using the J 25070, if necessary. 5. Ensure that the temperature of the emblem/nameplate is approximately 29-32°C (85-90°F). Important: Do not touch the adhesive backing of the emblem/nameplate. 6. Remove the protective liner from the back of the emblem/nameplate. 7. Position the emblem/nameplate to the location marks and press the emblem/nameplate to the mounting surface. 8. Apply equal pressure along the emblem/nameplate to uniformly bond the item to the mounting surface. 9. Remove the protective tape from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Tools Required J 38778Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Remove the wiper arms. 3. Disconnect the windshield wiper washer hose from the air inlet grille. 4. Use the J 38778 to remove the push-in retainers from the air inlet grille. 5. Remove the air inlet grille from the vehicle. Installation Procedure 1. Install the air inlet grille to the vehicle. 2. Install the push-in retainers to the air inlet grille. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Cowl Moulding / Trim > System Information > Service and Repair > Page 9764 3. Install the windshield wiper washer hose to the air inlet grille. 4. Install the wiper arms. 5. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair Upper Side Moulding / Trim: Service and Repair Molding Replacement - Body Side Tools Required J 25070 Heat Gun Removal Procedure 1. Apply tape for alignment marks to aid in the installation of the body side molding. 2. Use tape to protect the mounting surface during removal. 3. When removing a body side molding, heat the body side molding using a J 25070. Apply heat using a circular motion for about 30 seconds. Notice: Refer to Exterior Trim Emblem Removal Notice in Service Precautions. 4. Use a plastic, flat-bladed tool to remove the body side molding from the panel surface. 5. When replacing a body side molding, remove all adhesive as follows: * For body panels use a 3M(TM) Scotch Brite molding adhesive remover disk 3M(TM) P/N 07502 or equivalent. * For plastic panels use a lint-free cloth and Varnish Makers and Painters (VMP) naptha or a 50/50 mixture by volume of isopropyl alcohol and water to remove the adhesive. Installation Procedure Important: Apply the body side molding in an environment that is free from dust or other dirt that could come into contact with the sticky backing. Foreign material may cause improper adhesion. 1. Clean the area where the body side molding will be installed. Use a lint free cloth and Varnish Makers and Painters (VMP) naptha or a 50/50 mixture by volume of isopropyl alcohol and water to clean the area. 2. Dry the area thoroughly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Service and Repair > Page 9768 3. Apply tape and mark the location as shown. 4. Heat the mounting surface to approximately 27-41°C (80-105°F). 5. Ensure that the temperature of the body side molding is approximately 29-32°C (85-90°F). Important: Do not touch the adhesive backing of the body side molding. 6. Remove the protective liner from the back of the body side molding. 7. Position the body side molding to the location marks and press the molding to the mounting surface. 8. Apply equal pressure along the body side molding to uniformly bond the item to the mounting surface. 9. Remove the protective tape from the mounting surface. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Procedures Windshield Moulding / Trim: Procedures Stationary Window Reveal Molding Repair Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: The window reveal molding fills the cavity between the body and window. If the reveal molding is stretched or damaged, it cannot be reused and it must be replaced. 1. Lift up on the loose area of the reveal molding. 2. Clean the top edge of the window surface and the reveal molding with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint-free cloth. 3. If the reveal molding cannot be reused, refer to Stationary Window Reveal Molding Repair. Installation Procedure Caution: Refer to Window Retention Caution in Service Precautions. 1. Verify all primers and urethane adhesive are within expiration dates. Important: Use care when applying the prep, clear #1, to the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly. 2. Use a new dauber in order to apply glass prep, clear #1, to the channel area approximately 13 mm (1/2 in) to the upper edge of the window. 3. Wipe the glass primed area immediately with a clean lint-free cloth. 4. Shake the glass primer, black #2, for at least 1 minute. 5. Use a new dauber in order to apply glass primer, black #2, to the top edge of the window. 6. Apply a small bead of urethane adhesive (2) between the window (1) and the pinch-weld. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Procedures > Page 9773 7. Reinstall the window reveal molding. 1. Start from the loose area and hand-press the reveal molding into place over the edge of the window. 2. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. 3. Tape should be applied in order to retain the reveal molding to the window. This will maintain a flush fit with the body. 4. The tape is to be removed after 6 hours. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Windshield Moulding / Trim > Component Information > Service and Repair > Procedures > Page 9774 Windshield Moulding / Trim: Removal and Replacement Windshield Reveal Molding Replacement The windshield reveal molding is an applied molding design separate from the window. The reveal molding is bonded by to the windshield and may be bonded to the body. The reveal molding may be replaced with the windshield as an assembly, or the reveal molding may be available as a separate service part. Refer to Urethane Adhesive Installation of Stationary Windows. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair Front Fender Liner: Service and Repair Front Fender Liner Replacement Removal Procedure 1. Drill out the plastic rivets from the front fascia extension corner to front fender liner, if equipped. 2. Remove the screws from the front fender liner at the front bumper fascia. 3. Remove the nut from the stud at the rear of the front fender liner. 4. Remove the bolt from the front tab of the front fender liner at the lower engine compartment side rail. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Page 9780 5. Remove the screws from the front fender liner. 6. Drill out the plastic rivet from the front rocker panel to front fender liner, if equipped. 7. Remove the front fender liner. Installation Procedure 1. Position the fender liner to the fender, over the stud and behind the rocker molding. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the nut to the stud at the rear of the front fender liner. Tighten the front fender liner stud nut to 4 N.m (35 lb in). 3. Install the screws to the front fender liner at the front bumper fascia. Tighten the front fender liner to front bumper fascia screws to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Fender > Front Fender > Front Fender Liner > System Information > Service and Repair > Page 9781 4. Install the screws to the front fender liner. Tighten the front fender liner screws to 2 N.m (18 lb in). 5. Using a new plastic rivet, install the plastic rivet to the rocker panel and front fender liner, if equipped. 6. Install the bolt to the front tab of the front fender liner at the lower engine compartment side rail. Tighten the front fender liner to rear of fender bolt to 7 N.m (61 lb in). 7. Using new plastic rivets, install the plastic rivets to the front fascia extension corner and front fender liner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair Rear Fender Liner: Service and Repair Wheelhouse Liner Panel Replacement - Rear Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the rear tires and wheels. 3. Remove the rocker panel to rear wheelhouse liner screw. 4. Remove the quarter panel to rear wheelhouse liner screws. 5. Remove the lower quarter panel to rear wheelhouse liner screw. 6. Using J 38778 remove the lower quarter panel to rear wheelhouse liner push-in retainer. 7. Remove the rear wheelhouse liner to rear wheelhouse palnuts. 8. Remove the rear wheelhouse liner from the vehicle. Installation Procedure 1. Align the rear wheelhouse liner to the rear wheelhouse. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear wheelhouse liner to rear wheelhouse palnuts. Tighten the rear wheelhouse liner to rear wheelhouse palnuts to 2 N.m (18 lb in). 3. Install the lower quarter panel to rear wheelhouse liner push-in retainer. 4. Install the lower quarter panel to rear wheelhouse liner screw. Tighten the lower quarter panel to rear wheelhouse liner screw to 2 N.m (18 lb in). 5. Install the quarter panel to rear wheelhouse liner screws. Tighten the quarter panel to rear wheelhouse liner screws to 2 N.m (18 lb in). 6. Install the rocker panel to rear wheelhouse liner screw. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Fender > Rear Fender > Rear Fender Liner > System Information > Service and Repair > Page 9786 Tighten the rocker panel to rear wheelhouse liner screw to 2 N.m (18 lb in). 7. Install the rear tires and wheels. 8. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Firewall > Component Information > Service and Repair Firewall: Service and Repair Engine Dash Mat Replacement - Side The engine side dash mat is composed of a thermoplastic rubber. The material is flexible, so the most desirable way to service the dash mat or to make any repair behind it is locally pull away or remove the dash mat. In many cases, the dash mat can be pulled away in one area so that a repair can be made behind it. However, there may be an instance where it is necessary to cut the dash mat in order to make a repair. Although it is not desirable to cut the dash mat, if it becomes necessary, the recommended procedure to repair the cut is as follows: 1. Prepare the surface surrounding the cut by lightly sanding the area. 2. Apply contact cement between the cut surface and the surrounding area. 3. Allow the cement to cure before stressing the repaired area. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Frame Cushion or Insulator Replacement - Front Body / Frame Mount Bushing: Service and Repair Frame Cushion or Insulator Replacement - Front Frame Cushion or Insulator Replacement - Front Tools Required J 45296 Frame Insulator Remover/Installer Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Disconnect the steering intermediate shaft. 3. Disconnect the fog lamp electrical connectors from the fog lamps. 4. Install a jackstand under the center of the frame, between the front frame insulators. 5. Remove the front frame bolts and retainers. 6. Lower the front of the frame. 7. Remove the frame front upper insulators. 8. Install the J 45296, or equivalent to the front frame insulator you are removing. 9. Using the J 45296, or equivalent remove the front frame insulator from the frame. Installation Procedure 1. Clean the front frame insulator opening. 2. Apply a thin coat of rubber lubricant GM P/N 01051717 (Canadian P/N 12345884) or equivalent to the inside of the front frame insulator opening. 3. Apply a thin coat of rubber lubricant GM P/N 01051717 (Canadian P/N 12345884) or equivalent to the front frame insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Frame Cushion or Insulator Replacement - Front > Page 9795 4. Align the front frame insulator to the front frame opening with the front frame alignment tabs facing to the front. 5. Using the J 45296,or equivalent install the front frame insulator to the front frame. 6. Install the frame front upper insulators. 7. Raise the front of the frame. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the front frame bolts and retainers. Tighten the front frame bolts to 160 N.m (118 lb ft). 9. Remove the jackstand. 10. Connect the fog lamp electrical connectors to the fog lamps. 11. Connect the steering intermediate shaft. 12. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Frame Cushion or Insulator Replacement - Front > Page 9796 Body / Frame Mount Bushing: Service and Repair Frame Cushion or Insulator Replacement - Rear Frame Cushion or Insulator Replacement - Rear Removal Procedure Important: In order to remove any frame insulator, loosen the adjacent frame insulators to permit the frame to separate from the body. Do not break the fan shroud or damage the frame attachments, such as steering hoses and brake pipes during the replacement of body mounts. When installing a body mount, ensure the lower insulator is seated into the frame. The lower insulator should not be loose. The spacer and the corresponding upper insulator is pressed into the lower insulator thus squeezing the frame. The bolt is then inserted through the mount, capturing the lower retainer. The body mount components prevent contact of the frame to the body. Do not over tighten the body mount. Over tightening may collapse a spacer or strip a bolt. When the frame insulator bolts are removed, always discard the bolts and replace with new bolts. When clamping by the mount, ensure the surfaces are clean and dry. If the frame insulator bolt does not screw in smoothly, run a tap through the frame crossmember nut in the body in order to remove foreign material. Ensure the tap does not punch through the underbody. Whenever the body is moved in relation to the frame, disconnect the intermediate shaft from the rack and pinion steering gear and stub shaft. 1. Raise and suitably support the vehicle. Refer to Vehicle Lifting. 2. Remove the intermediate shaft from the steering gear stub shaft. 3. Install a utility stand to the rear of the frame. 4. Remove the rear frame bolts. 5. Lower the rear of the frame. 6. Remove the upper and lower insulators from the rear of the frame as a set. Installation Procedure 1. Apply lube to inside surface of lower insulator and to top surface of upper insulator. 2. Install the upper and lower insulators to the rear of the frame as a set. 3. Raise the rear of the frame. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Body / Frame Mount Bushing > Component Information > Service and Repair > Frame Cushion or Insulator Replacement - Front > Page 9797 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the rear frame bolts. Tighten the rear frame bolts to 165 N.m (122 lb ft). 5. Remove the utility stand. 6. Install the intermediate shaft to the steering gear stub shaft. 7. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair Cross-Member: Service and Repair Brace Replacement - Cross Vehicle Removal Procedure 1. Open the hood. 2. Remove the nuts from the cross vehicle brace. 3. Remove the cross vehicle brace from the vehicle. Important: Be careful, the stud plates may fall out and possibly get caught under the vehicle during the removal. 4. Remove the stud plates push on nuts from the studs. 5. Remove the stud plates from the vehicle. Installation Procedure Important: The stud plates will require an assistant to hold the stud plates during the installation of the push on nuts. 1. Install the stud plates to the vehicle. 2. Install the stud plates push on nuts to the studs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Service and Repair > Page 9801 3. Install the cross vehicle brace to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the nuts to the cross vehicle brace. Tighten the cross vehicle brace nuts to 18 N.m (13 lb ft). 5. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair Front Subframe: Service and Repair Frame Replacement Tools Required J 39580 Universal Engine Support Table Removal Procedure 1. Install the engine support fixture. 2. Raise and support the vehicle. Refer to Vehicle Lifting. 3. Remove the front tires and wheels. 4. Remove the lower radiator air deflector. 5. Remove the positive battery cable retainers. Position the positive battery cable aside. 6. Disconnect the power steering cooler pipe from the frame. 7. Secure the power steering cooler to the exhaust pipe. 8. Remove the stabilizer shaft links. Rotate the stabilizer shaft up to gain access to the mounting bolts for the power steering gear. 9. Remove the mounting bolts for the power steering gear. 10. Secure the power steering gear. 11. Remove the nuts which secure the engine mount to the frame. 12. Remove the nuts which secure the transaxle mount to the frame. 13. Disconnect both front wheel speed sensor connectors (1), if equipped. 14. Remove both front wheel speed harness retainers (2) from the frame and the lower control arms, if equipped. 15. Separate both of the lower ball joints from the steering knuckle. Refer to Lower Ball Joint Replacement in Front Suspension. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 9806 16. Lower the vehicle until the frame contacts J 39580. 17. Remove the bolts which secure the front frame to the body. 18. Remove the bolts which secure the rear frame to the body. 19. Raise the vehicle in order to separate the frame from the body. 20. If you are replacing the frame, remove the following components: * Both of the lower control arms. Refer to Lower Control Arm Replacement in Front Suspension. * The stabilizer shaft. Refer to Stabilizer Shaft Replacement in Front Suspension. * The spacers, the upper insulator, the lower insulator, and the retainers. Refer to Frame Cushion or Insulator Replacement - Front and to Frame Cushion or Insulator Replacement - Rear. Installation Procedure 1. If you are replacing the frame, install the following components: * Both of the lower control arms. Refer to Lower Control Arm Replacement in Front Suspension. * The stabilizer shaft. Refer to Stabilizer Shaft Replacement in Front Suspension. * The spacers, the upper insulator, the lower insulator, and the retainers. Refer to Frame Cushion or Insulator Replacement - Front and to Frame Cushion or Insulator Replacement - Rear. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 9807 2. Position the engine support table with the frame under the vehicle. 3. Lower the vehicle to the frame. 4. Loosely install the bolts to secure the rear frame to the body. 5. Loosely install the bolts to secure the front and rear frame to the body. Notice: Refer to Fastener Notice in Service Precautions. 6. Align the frame to the body by inserting two 19X203 mm (0.74X8.0 in) pins in the alignment holes on the right side of the frame. * Tighten the new front frame bolts to 160 N.m (118 lb ft). * Tighten the new rear frame bolts to 165 N.m (122 lb ft). 7. Connect both the lower ball joints to the steering knuckle. 8. Install the nuts which secure the engine mount to the frame. * Engine Mount Replacement in Engine - 3.4L * Engine Mount and Bracket Replacement in Engine - 3.8L 9. Install the nuts which secure the transaxle mount to the frame. 10. Remove the power steering gear from the exhaust pipe. Position to the frame. 11. Install the steering gear mounting bolts. 12. Install the stabilizer shaft links. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Frame > Subframe > Front Subframe > System Information > Service and Repair > Page 9808 13. Connect both front wheel speed sensor connectors (1), if equipped. 14. Install both front wheel speed harness retainers (2) to the frame and to the lower control arm, if equipped. 15. Install the positive battery cable. 16. Install the power steering cooler pipe. 17. Install the radiator lower air deflector. 18. Install the front tires and wheels. 19. Lower the vehicle. 20. Remove the engine support fixture. 21. Inspect the front wheel alignment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair Grille: Service and Repair Fascia Grille Replacement Tool Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Remove the upper radiator air baffle. 3. Using J 38778 remove the push-in retainers from the upper grille. 4. Remove the circle retainers from the ends of the grille. 5. Pull forward and up to release the grille retainers. Remove the grille from the front bumper fascia. Installation Procedure 1. Align the lower retainer tabs of the grille to the front bumper fascia. 2. Install the lower grille to the front bumper fascia by pressing down until the tabs are fully seated. 3. Align the outer location pins by manipulating the front bumper fascia and pressing in the grille until fully seated. 4. Install the circle retainers to the ends of the grille. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Grille > Component Information > Service and Repair > Page 9812 5. Install the push-in retainers to the upper grille. 6. Install the upper radiator air baffle. 7. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Ashtray and Housing Replacement - Front Seat (Impala) Arm Rest: Service and Repair Ashtray and Housing Replacement - Front Seat (Impala) Ashtray and Housing Replacement - Front Seat (Impala) Removal Procedure 1. Open the ashtray. 2. Depress the ashtray retainer. 3. Remove the ashtray from the ashtray housing. 4. Remove the ashtray housing, by pressing down with your thumbs and pulling out from the armrest housing base. Installation Procedure 1. Position the ashtray housing to the armrest base. 2. Install the ashtray housing, pressing into place until fully seated. 3. Install the ashtray, pressing into place until fully seated. 4. Close the ashtray. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Arm Rest > Component Information > Service and Repair > Ashtray and Housing Replacement - Front Seat (Impala) > Page 9818 Arm Rest: Service and Repair Console Armrest Replacement - Front Floor Console Armrest Replacement - Front Floor Removal Procedure 1. Raise the front floor console armrest. 2. Remove the screws from the console armrest hinge. 3. Remove the console armrest. Installation Procedure 1. Install the armrest to the hinge at the front floor console. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to console armrest hinge. Tighten the screws to 2 N.m (18 lb in). 3. Lower the console armrest. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Technical Service Bulletins > Customer Interest for Ash Tray: > 04-08-49-031 > Dec > 04 > Interior - Ash Tray Will Not Open Ash Tray: Customer Interest Interior - Ash Tray Will Not Open Bulletin No.: 04-08-49-031 Date: December 07, 2004 TECHNICAL Subject: Ash Tray Will Not Open (Reposition Ash Tray Reflector Flap, Replace Ash Tray, if Necessary) Models: 2000-2004 Chevrolet Impala Condition Some customers may comment that the ash tray housing will not open. Cause This condition may be caused by the ash tray reflector flap folded forward causing the ash tray not to open. Correction Remove and reinstall the ash tray. 1. Open the ash tray as seen in the illustration above. 2. Push the ash tray forward and hold the reflector flap down with a screw driver as seen in the illustration above. Pull rearward. This will allow the ash tray reflector flap to pass by the housing and fully open. 3. Replace the ash tray receptacle if damaged. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Technical Service Bulletins > Customer Interest for Ash Tray: > 04-08-49-031 > Dec > 04 > Interior - Ash Tray Will Not Open > Page 9827 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ash Tray: > 04-08-49-031 > Dec > 04 > Interior - Ash Tray Will Not Open Ash Tray: All Technical Service Bulletins Interior - Ash Tray Will Not Open Bulletin No.: 04-08-49-031 Date: December 07, 2004 TECHNICAL Subject: Ash Tray Will Not Open (Reposition Ash Tray Reflector Flap, Replace Ash Tray, if Necessary) Models: 2000-2004 Chevrolet Impala Condition Some customers may comment that the ash tray housing will not open. Cause This condition may be caused by the ash tray reflector flap folded forward causing the ash tray not to open. Correction Remove and reinstall the ash tray. 1. Open the ash tray as seen in the illustration above. 2. Push the ash tray forward and hold the reflector flap down with a screw driver as seen in the illustration above. Pull rearward. This will allow the ash tray reflector flap to pass by the housing and fully open. 3. Replace the ash tray receptacle if damaged. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ash Tray: > 04-08-49-031 > Dec > 04 > Interior - Ash Tray Will Not Open > Page 9833 Parts Information Parts are currently available from GMSPO. Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Procedures Ash Tray: Procedures Ashtray Replacement ASHTRAY REPLACEMENT REPLACEMENT PROCEDURE 1. Remove the instrument panel (IP) cluster trim plate. 2. Remove the IP ashtray. 3. Remove the IP ashtray bracket screws (1). 4. Remove the IP ashtray bracket. 5. Disconnect the electrical connector from the ashtray. INSTALLATION PROCEDURE 1. Connect the electrical connector to the ashtray. 2. Install the IP ashtray bracket to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the IP ashtray bracket screws (1). Tighten Tighten the screws to 2 N.m (18 lb in). 4. Install the IP ashtray. 5. Install the IP cluster trim plate. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Procedures > Page 9836 Ashtray and Housing Replacement - Front Seat ASHTRAY AND HOUSING REPLACEMENT - FRONT SEAT (IMPALA) REMOVAL PROCEDURE 1. Open the ashtray. 2. Depress the ashtray retainer. 3. Remove the ashtray from the ashtray housing. 4. Remove the ashtray housing, by pressing down with your thumbs and pulling out from the armrest housing base. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Procedures > Page 9837 1. Position the ashtray housing to the armrest base. 2. Install the ashtray housing, pressing into place until fully seated. 3. Install the ashtray, pressing into place until fully seated. 4. Close the ashtray. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Ash Tray > Component Information > Service and Repair > Procedures > Page 9838 Ash Tray: Removal and Replacement Ashtray Replacement Replacement Procedure 1. Remove the instrument panel (IP) cluster trim plate. 2. Remove the IP ashtray. 3. Remove the IP ashtray bracket screws (1). 4. Remove the IP ashtray bracket. 5. Disconnect the electrical connector from the ashtray. Installation Procedure 1. Connect the electrical connector to the ashtray. 2. Install the IP ashtray bracket to the instrument panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the IP ashtray bracket screws (1). Tighten the screws to 2 N.m (18 lb in). 4. Install the IP ashtray. 5. Install the IP cluster trim plate. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats Carpet: Technical Service Bulletins Interior - Proper Use of Floor Mats INFORMATION Bulletin No.: 10-08-110-001 Date: March 30, 2010 Subject: Information on Proper Use of Floor Mats Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2003-2009 HUMMER H2 2006-2010 HUMMER H3, H3T 2005-2009 Saab 9-7X GM's carpeted and all-weather (rubber) floor mats are especially designed for use in specific GM vehicles. Using floor mats that were not designed for the specific vehicle or using them incorrectly may cause interference with the accelerator or brake pedal. Please review the following safety guidelines regarding proper driver's side floor mat usage with the customer. Warning If a floor mat is the wrong size or is not properly installed, it can interfere with the accelerator pedal and/or brake pedal. Interference with the pedals can cause unintended acceleration and/or increased stopping distance which can cause a crash and injury. Make sure the floor mat does not interfere with the accelerator or brake pedal. - Do not flip the driver's floor mat over (in an effort to keep the floor mat clean) - Do not place anything on top of the driver's floor mat (e.g. carpet remnant, towel) - Do not place another mat on top of the driver's floor mat (e.g. do not place all-weather rubber mats over carpeted floor mats) - Only use floor mats that are designed specifically for your vehicle - When using replacement mats, make certain the mats do not interfere with the accelerator or brake pedal before driving the vehicle If your vehicle is equipped with a floor mat retaining pin(s) or clip(s), make certain the mat is installed correctly and according to the instructions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 9843 After installing floor mats, make certain they cannot move and do not interfere with the accelerator or brake pedals. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 9844 Carpet: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 9845 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Technical Service Bulletins > Interior - Proper Use of Floor Mats > Page 9846 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures Carpet: Procedures Eliminating Unwanted Odors in Vehicles Eliminating Unwanted Odors in Vehicles GM Vehicle Care Odor Eliminator, GM P/N 12378554, US ACDelco 88900909, Canadian P/N 88901678, may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. This non-toxic, biodegradable, odorless product has been shown to greatly reduce or remove the following types of odor: * Objectionable smells of mold and mildew resulting from vehicle water leaks * Customer created odors, such as smoke You may safely use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet, and sound deadening materials. You may also induce this product into HVAC modules and instrument panel ducts for the control of non-bacterial related odors. Important: This product leaves no residual scent and should not be used as an air freshener. This product may result in the permanent elimination of an odor and may be preferable to customers whose allergies make them sensitive to perfumes. This product may effectively remove odors when directly contacting the odor source. In cases such as water leaks, use this product with diagnostic procedures to first eliminate the primary cause of the odor. Then use further applications on the residual odor to permanently correct the vehicle condition. How to Use this Product * Spray GM Vehicle Care Odor Eliminator directly or as an additive with carpet shampoo in steam cleaners. * Do not use on any interior surface that plain water would deteriorate, because this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of GM Vehicle Care Odor Eliminator. * Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a persistent or recurring odor, you may call to obtain additional information and usage suggestions. Floor Carpet Drying Floor Carpet Drying If the carpet or the pad or insulator is wet, use the following criteria for drying or for replacing the components: * For a 1-piece carpet assembly bonded to a cotton or a fiber padding, replace the entire assembly. * For a 2-piece carpet assembly with a cotton or a fiber padding, replace the padding only. While the carpet is out of the vehicle, dry the carpet using the method described below. * For a 1-piece carpet assembly bonded to a foam padding or attached to a synthetic padding, dry the carpet using the method described below. * For a 2-piece carpet assembly with a synthetic padding, dry the assembly using the method described below. Drying Method 1. If you observe puddles of liquid on the carpet face, use a wet vacuum to remove the excess moisture. 2. Blot the face of the carpet with a towel in order to absorb as much moisture as possible. 3. Point a fan at the affected area and air dry the carpet. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 9849 Carpet: Removal and Replacement Carpet Replacement - Front Carpet Replacement - Front Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Remove the front seats. 2. Remove the front floor center console, if equipped. 3. Remove the rear seat cushion. 4. Remove the front seat carpet retainers. 5. For the Impala, remove the following components: 1. The lower trim panel. Refer to Trim Panel Replacement - Rear Quarter Lower (Impala) Trim Panel Replacement - Rear Quarter Lower (Monte Carlo). 2. The center pillar lower trim panel. Refer to Trim Panel Replacement - Lower Center Pillar (Impala). 6. Remove the rear lower quarter trim panel. 7. Using J 38778, remove the push-in retainers that secure the carpet on top of the rocker panels. 8. Remove the carpet from the vehicle. Installation Procedure Caution: In order to avoid personal injury or vehicle damage when you repair or replace the carpet, use the same thickness and material size as the original installation. Always return the carpet to the original location. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 9850 1. Install the carpet into the vehicle. Reach under the carpet and feed the following connectors through the slits in the carpet where required: * The power seat adjusters * The center console power port * The seat belt warning wire connector 2. Install the push-in retainers that secure the carpet on top of the rocker panels. 3. Install the rear quarter lower trim. 4. For the Impala, install the following components: 1. The center pillar lower trim panel. Refer to Trim Panel Replacement - Lower Center Pillar (Impala). 2. The lower trim panel. Refer to Trim Panel Replacement - Rear Quarter Lower (Impala) Trim Panel Replacement - Rear Quarter Lower (Monte Carlo). 5. Install the front seat carpet retainers. 6. Install the rear seat cushion. 7. Install the front floor center console, if equipped. 8. Install the front seats. Carpet Retainer Replacement - Front Carpet Retainer Replacement - Front Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Carpet > Component Information > Service and Repair > Procedures > Page 9851 1. Remove the front door opening carpet retainer using J 38778. 2. Remove the front door opening carpet retainer from the vehicle. Installation Procedure 1. Align the front door opening carpet retainer to the push-in nuts and to the front door weatherstripping. 2. Install the door opening carpet retainer to the push-in nuts, applying pressure to secure at all tab locations. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 03-08-49-018A > Apr > 04 > Interior - Console Lid Latch Broken Console: Customer Interest Interior - Console Lid Latch Broken Bulletin No.: 03-08-49-018A Date: April 20, 2004 TECHNICAL Subject: Broken Console or Storage Compartment Lid Latch (Replace Latch) Models: 1997-2004 Buick Century, Regal 2000-2004 Chevrolet Impala, Monte Carlo Supercede: This bulletin is being revised to add models and revise the Parts Information. Please discard Corporate Bulletin Number 03-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment on a broken console or storage compartment lid latch. Cause In most cases, customers are unaware of the latches proper operation and may apply excessive force to the lid. Additionally, the latch may take excessive force if the console is subjected to downward force such as being kneeled, or sat on. Correction Important: Replace only the latch. Do not replace the console lid and/or armrest assembly. Replace the latch. The latch assembly is sold as a separate part for the vehicles listed above. The latch is retained by two screws in the latch assembly. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Customer Interest for Console: > 03-08-49-018A > Apr > 04 > Interior - Console Lid Latch Broken > Page 9860 Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 03-08-49-018A > Apr > 04 > Interior - Console Lid Latch Broken Console: All Technical Service Bulletins Interior - Console Lid Latch Broken Bulletin No.: 03-08-49-018A Date: April 20, 2004 TECHNICAL Subject: Broken Console or Storage Compartment Lid Latch (Replace Latch) Models: 1997-2004 Buick Century, Regal 2000-2004 Chevrolet Impala, Monte Carlo Supercede: This bulletin is being revised to add models and revise the Parts Information. Please discard Corporate Bulletin Number 03-08-49-018 (Section 08 - Body and Accessories). Condition Some customers may comment on a broken console or storage compartment lid latch. Cause In most cases, customers are unaware of the latches proper operation and may apply excessive force to the lid. Additionally, the latch may take excessive force if the console is subjected to downward force such as being kneeled, or sat on. Correction Important: Replace only the latch. Do not replace the console lid and/or armrest assembly. Replace the latch. The latch assembly is sold as a separate part for the vehicles listed above. The latch is retained by two screws in the latch assembly. Parts Information Parts are currently available from GMSPO. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Console: > 03-08-49-018A > Apr > 04 > Interior - Console Lid Latch Broken > Page 9866 Warranty Information For vehicles repaired under warranty, use the table shown. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Technical Service Bulletins > Page 9867 Console: Specifications Fastener Tightening Specifications Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor Console: Service and Repair Console Armrest Replacement - Front Floor Console Armrest Replacement - Front Floor Removal Procedure 1. Raise the front floor console armrest. 2. Remove the screws from the console armrest hinge. 3. Remove the console armrest. Installation Procedure 1. Install the armrest to the hinge at the front floor console. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws to console armrest hinge. Tighten the screws to 2 N.m (18 lb in). 3. Lower the console armrest. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 9870 Console: Service and Repair Console Replacement - Front Floor Console Replacement - Front Floor (Impala) Removal Procedure 1. Remove the trim plate from the front floor console. 2. Remove the following front floor console bolts: * Near the instrument panel (IP) * At the transaxle shift control lever * Under the mat in the rear bin 3. Pull the console rearward in order to disengage the clips from the IP. 4. Disconnect the electrical connectors. 5. Remove the front floor console. Installation Procedure 1. Position the front floor console to the vehicle. 2. Connect the electrical connectors. 3. Install the front floor console. Engage the clips at the IP. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 9871 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the following front floor console bolts: * Near the instrument panel (IP) * At the transaxle shift control lever * Under the mat in the rear bin Tighten the bolts to 12 N.m (106 lb in). 5. Install the trim plate to the front floor console. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 9872 Console: Service and Repair Console Replacement - Overhead Console Replacement - Overhead Removal Procedure 1. Remove the screw from the front of the console. Important: The overhead console retainers are located on the switch side of the assembly. 2. Use a small, flat-bladed tool in order to release the 2 retainers. Press the retainers to the side to release the assembly. 3. Remove the overhead console from the headliner. 4. Disconnect the electrical connectors from the overhead console. 5. Remove the overhead console from the vehicle. 6. Remove the screws from the drivers information center module. 7. Remove the drivers information center module from the overhead console. Installation Procedure 1. Install the drivers information center module to the overhead console. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 9873 2. Install the drivers information center module screws. Tighten the screws to 2 N.m (18 lb in). Important: When installing the overhead console, apply a foam type tape to the wiring harness to relocate and secure the wiring harness in the proper position to the headliner. 3. Apply foam tape to the wiring harness at the headliner. 4. Connect the electrical connector to the overhead console. 5. Position the overhead console to the mounting bracket in the headliner. 6. Install the overhead console pressing into place to fully seat the retainers (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 9874 Console: Service and Repair Roof Console Retainer Replacement Roof Console Retainer Replacement Removal Procedure 1. Remove the overhead console. 2. Remove the sunshade anchors. 3. Lower the headliner at the sunroof opening. 4. Remove the foam tape from the electrical harness on the console retainer (2). 5. Reposition the electrical harness away from the retainer. 6. Slide the retainer forward and remove the retainer from the front of the headliner. 7. Remove the remote compass sensor. Installation Procedure 1. Install the remote compass sensor in the console retainer. 2. Slide the retainer (2) under the front edge of the headliner to the installed position. 3. Position the electrical harness in the retainer and tape the harness into place. 4. Install the sunshade anchors. 5. Install the overhead console. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Console Armrest Replacement - Front Floor > Page 9875 Console: Service and Repair Trim Plate Replacement - Front Floor Console Trim Plate Replacement - Front Floor Console (Impala) Removal Procedure 1. Apply the park brake. 2. Shift the transaxle shift lever from Park to 2. 3. Open the storage compartment door. 4. Carefully pry the rear of the trim plate away from the front floor console. 5. Pull the trim plate towards the rear of the vehicle in order to disengage the front of the trim plate. 6. Disconnect the electrical connector at the rear of the front floor console trim plate. 7. Rotate the trim plate 180 degrees. Lift the trim plate over the shift control handle. 8. Disconnect the wiring harness retainers from the trim plate. 9. Disconnect the wiring harness. 10. Disconnect the cigar lighter electrical connector. 11. Remove the ashtray. 12. Remove the front floor console trim plate. Installation Procedure 1. Install the ashtray. 2. Connect the cigar lighter electrical connector. 3. Install the wiring harness. 4. Connect the wiring harness retainers to the trim plate. 5. Lower the trim plate over the shift control handle. Rotate the trim plate 180 degrees. 6. Connect the electrical connector at the rear of the trim plate. 7. Engage the trim plate. Ensure that the retainers are completely engaged. 8. Close the storage compartment door. 9. Shift the transaxle shift lever from 2 to Park. 10. Release the park brake. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and Repair > Page 9876 Console: Tools and Equipment Special Tools Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Disabling And Enabling Zones Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9882 The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9883 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the radiator upper air baffle and deflector. 7. Remove the orange connector position assurance (CPA) (2) from the yellow sensor harness connector (3). 8. Disconnect the sensor harness connector from the sensor (1). Zone 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9884 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the side impact sensor (SIS)-LF from the center pillar. 7. Remove the connector position assurance (CPA) from the SIS-LF connector (2). 8. Disconnect the SIS-LF connector (2) from the SIS-LF (1). Zone 3 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9885 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the LH insulator panel. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Disconnect the steering wheel module coil connector. Zone 5 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9886 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the RH IP access hole cover. 7. Remove the connector position assurance (CPA) from the inflatable restraint IP module connector located to the right of the steering column. 8. Disconnect the IP module connector. Zone 7 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9887 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the fuse block access cover. 5. Remove the SIR Fuse. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the side impact module - LF connector (1) located under the driver seat. 7. Disconnect the side impact module - LF connector (1). Zone 9 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9888 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the I/P fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the LH insulator panel. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Disconnect the steering wheel module coil connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9889 9. Remove the RH I/P access hole cover. 10. Remove the CPA from the inflatable restraint I/P module connector, located at the RH side of the I/P. 11. Disconnect the I/P module connector. 12. Remove the CPA from the inflatable restraint side impact module - LF connector (1), located under the driver seat. 13. Disconnect the side impact module - LF connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9890 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition. 2. Connect the sensor harness connector (3) to the sensor (1). 3. Install the orange CPA (2) into the yellow sensor harness connector (3). 4. Install the radiator upper air baffle and deflector. 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash seven times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9891 1. Connect the SIS-LF connector (2) to the SIS-LF (1). 2. Install the CPA to the SIS-LF connector(2). 3. Install the side impact sensor (SIS)-LF into the center pillar. 4. Install the SIR Fuse. 5. Install the fuse block access cover. 6. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. 2. Connect the steering wheel module coil connector. 3. Install the CPA from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 4. Install the LH insulator panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9892 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash seven times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the IP module connector. 3. Install the CPA into the IP module connector located to the right of the steering column. 4. Install the LH insulator panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9893 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Connect the inflatable restraint side impact module - LF connector (1) located under the driver seat. 2. Install the CPA to the side impact module - LF connector (1). 3. Remove the SIR Fuse. 4. Install the fuse block access cover. 5. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 5.1. The AIR BAG indicator will flash seven times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9894 1. Remove the key from the ignition. Connect the inflatable restraint side impact module - LF connector (1), located under the driver seat. 2. Install the CPA to the side impact module - LF connector. 3. Connect the inflatable restraint I/P module connector, located at the RH side of the I/P. 4. Install the CPA to the I/P module connector. 5. Install the RH I/P access hole cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 9895 6. Connect the steering wheel module coil connector. 7. Install the CPA from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Install the LH insulator panel. 9. Install the SIR Fuse. 10. Install the LH I/P access hole cover. 11. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 11.1. The AIR BAG indicator will flash seven times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information > Service and Repair Drink Holders: Service and Repair Armrest Cup Holder Replacement - Front Seat Removal Procedure 1. Open the armrest lid. 2. Rotate the cup holder to its open position. 3. Squeeze the mounting bracket of the cup holder assembly together to disengage the pins from the armrest storage box sides. 4. Remove the cup holder. Installation Procedure 1. Position the cup holder in the armrest. 2. Squeeze the mounting bracket of the cup holder assembly and insert the pins into the mounting holes. 3. Rotate the cup holder to its closed position. 4. Close the armrest lid. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock > Component Information > Adjustments Glove Compartment Lock: Adjustments STRIKER ADJUSTMENT - INSTRUMENT PANEL (I/P) COMPARTMENT 1. Open the instrument panel (IP) compartment door. 2. Loosen the IP compartment striker screws. 3. Adjust the IP compartment striker, as required. NOTE: Refer to Fastener Notice in Service Precautions. 4. Tighten the IP compartment striker screws. Tighten Tighten the striker screws to 2 N.m (18 lb in). 5. Close the IP compartment. 6. Inspect the IP compartment for proper fit and operation. Repeat the procedure if required. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock > Component Information > Adjustments > Page 9903 Glove Compartment Lock: Service and Repair LATCH REPLACEMENT - INSTRUMENT PANEL (I/P) COMPARTMENT REMOVAL PROCEDURE 1. Open the instrument panel (IP) compartment door. 2. Remove the outer door screws from the IP compartment. 3. Separate the outer door from the inner IP compartment. 4. Remove the screws which secure the IP compartment door latch (4) to the door. 5. Remove the U-clip (1) from the handle. 6. Begin to lift the door latch away from the door. Slide the latch to the right, then disconnect the latch rod (3) from the door handle. 7. Remove the door latch (2). INSTALLATION PROCEDURE 1. Connect the door latch rod (3) to the door handle (2). Lower the door latch into position on the door. 2. Install the U-clip (1) to the handle. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the retaining screws to the IP compartment door latch. Tighten Tighten the retaining screws to 2 N.m (18 lb in). 4. Install the outer door to the IP compartment. Install the outer door screws to the IP compartment. 5. Close the IP compartment door assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Service and Repair Glove Compartment Lock Cylinder: Service and Repair LOCK CYLINDER REPLACEMENT - INSTRUMENT PANEL (I/P) COMPARTMENT REMOVAL PROCEDURE 1. Remove the instrument panel (I/P) compartment door latch release handle. 2. Insert the key into the I/P compartment door lock cylinder. 3. Insert a small diameter tool into the slot on the side of the door lock cylinder housing. 4. Depress the tool into the lock cylinder slot and turn the key 1/4-turn clockwise. IMPORTANT: Note the position of the lock cylinder on removal for installation. 5. Remove the lock cylinder. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock Cylinder > Component Information > Service and Repair > Page 9907 1. Insert the key into the lock cylinder. 2. Align the lock cylinder to the same position used for removal. 3. Install the lock cylinder to the door lock cylinder housing. Press into place until fully seated. 4. Turn the key 1/4-turn counterclockwise in order to secure the lock cylinder retainer. 5. Remove the key from the lock cylinder. 6. Install the I/P compartment door latch release handle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair Headliner: Service and Repair Headliner Replacement (Impala) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure Caution: Do not attempt to repair or alter the head impact energy-absorbing material glued to the headliner or to the garnish trims. If the material is damaged, replace the headliner and/or the garnish trim. Failure to do so could result in personal injury. 1. Remove the sunshades. 2. Remove the sunshade anchors. 3. Remove the dome lamp, if equipped. 4. Remove the assist handles, if equipped. 5. Remove the coat hook. 6. Remove the side rail lamps, if equipped. 7. Remove the windshield pillar garnish molding. 8. Remove the windshield rear view mirror electrical connector. 9. Remove the center pillar, upper trim panel. 10. Remove the rear seatback. 11. Remove the upper quarter trim panels. 12. Remove the rear window trim panel. 13. Remove the push-in retainers from the rear of the headliner using J 38778. With the aid of an assistant, support the front of the headliner. 14. Disconnect the headliner electrical harness connector and the ground wire. 15. Remove the headliner wiring harness from the inner roof panel. 16. Recline the front seats in order to aid in the removal of the headliner from the vehicle. 17. Move the console shifter all the way back to the number 1 position. 18. For the headliner without the sunroof, remove the headliner from the roof insulator pad, using a flat-bladed tool to cut through the glue bonding the headliner to the roof insulator pad. 19. For the headliner with the sunroof, remove the headliner from the sunroof module by disengaging the Velcro(TM) strips (1). 20. With the aid of an assistant, remove the headliner from the vehicle through the right front door. Installation Procedure Important: Excessive bending can deform the headliner during the installation. Use care when loading the headliner into the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Headliner > Component Information > Service and Repair > Page 9911 1. With the aid of an assistant, move the headliner into the vehicle through the right front door. 2. Position the headliner to the roof by aligning the sunshade holes in the headliner with the respective hole in the roof structure. 3. Connect the headliner electrical connector and the ground wire. 4. Install the headliner wiring harness to the inner roof panel. 5. Install the front assist handle, if equipped. 6. Install the sunshades. 7. Install the sunshade anchors. 8. Install the rear assist handles, if equipped. 9. Install the 2 rear push-in retainers to the rear of the headliner. 10. For the headliner with the sunroof, install the headliner to the sunroof module by engaging the Velcro(TM) strips (1). 11. Install the rear window trim panel. 12. Install the rear quarter upper trim panels. 13. Install the center pillar, upper trim panel. 14. Install the windshield pillar garnish molding. 15. Install the side rail lamps, if equipped. 16. Install the coat hook. 17. Install the dome lamp, if equipped. 18. Install the rear seat back. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Assist Handle Replacement - Front Passenger Assist Handle: Service and Repair Assist Handle Replacement - Front Assist Handle Replacement - Front Removal Procedure 1. Pull down on the assist handle. 2. Remove the plastic cover with a small, flat-bladed tool to expose the screws. 3. Remove the assist strap screws (1). 4. Remove the assist strap from the vehicle. Installation Procedure 1. Install the assist strap to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the assist strap screws (1). Tighten the screws to 2 N.m (18 lb in). 3. Install the plastic cover. Press the cover into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Passenger Assist Handle > Component Information > Service and Repair > Assist Handle Replacement - Front > Page 9916 Passenger Assist Handle: Service and Repair Assist Handle Replacement - Rear Assist Handle Replacement - Rear Removal Procedure 1. Pull down on the assist handle. 2. Use a small, flat-bladed tool to remove the plastic cover. 3. Remove the assist strap screws (2). 4. Remove the assist strap from the vehicle. Installation Procedure 1. Install the assist strap to the vehicle. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the assist strap screws (2). Tighten the screws to 2 N.m (18 lb in). 3. Install the plastic cover. Press the cover into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Rear Shelf > Component Information > Service and Repair Rear Shelf: Service and Repair TRIM PANEL REPLACEMENT - REAR WINDOW SHELF (IMPALA) REMOVAL PROCEDURE 1. Remove the rear seat cushion. 2. Remove the rear seat back. 3. Remove the rear upper quarter trim panel. 4. Remove the push-in retainers from the front of the rear window trim panel. 5. Lift the rear window trim panel and remove the seat belts through the slots in the rear window trim panel. 6. Slide the rear window trim panel forward to disengage the integral hook from the retaining hole and remove the rear window trim panel. INSTALLATION PROCEDURE 1. Slide the rear window trim panel rearward to engage the integral hook in the retaining hole. 2. Lift the rear window trim panel and route the seat belts through the slots in the rear window trim panel. 3. Install the push-in retainers to the front edge of the rear window trim panel. 4. Install the rear quarter upper trim panel. 5. Install the rear seat back. 6. Install the rear seat cushion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Scuff Plate > Component Information > Service and Repair Scuff Plate: Service and Repair Compartment Sill Plate Replacement - Rear Removal Procedure 1. Open the rear compartment. 2. Pull up on the rear compartment sill plate to release the spring clips. 3. Remove the rear compartment sill plate from rear compartment. Installation Procedure 1. Align the spring clips to slots in rear compartment. 2. Press down on the rear compartment sill plate with even pressure until fully seated. 3. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Customer Interest for Sun Visor: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Sun Visor: Customer Interest Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Bulletin No.: 06-08-42-002A Date: January 23, 2007 TECHNICAL Subject: Sunshade (Visor) Vanity Mirror Bulb Inoperative (Replace Vanity Mirror Bulb Only) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2005-2007 Cadillac STS 2001-2005 Chevrolet Impala, Monte Carlo 2001-2006 Chevrolet Silverado Crew Cab, Suburban, Tahoe 2001-2006 GMC Sierra Crew Cab, Yukon, Yukon XL 2004-2005 Pontiac Grand Prix 2006-2007 HUMMER H3 Supercede: This bulletin is being updated to add the 2007 model year. Please discard Corporate Bulletin Number 06-08-42-002 (Section 08 - Body & Accessories). Condition Some customers may comment that a sunshade (visor) vanity mirror bulb is inoperative. Cause This condition may be caused by an inoperative bulb. Correction Do NOT replace the entire sunshade (visor) assembly. Replace the sunshade (visor) vanity mirror bulb with P/N 9442395 if repairing one of the affected models covered for an inoperative vanity mirror bulb. Refer to Vanity Mirror Lamp Replacement in SI. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > Customer Interest for Sun Visor: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. > Page 9931 The vanity mirror bulb can be accessed by removing the lens. Place a flat-bladed tool in the notches and gently pry out the lens. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Visor: > 06-08-42-002A > Jan > 07 > Interior Lighting Sun Visor Vanity Mirror Lamp Inop. Sun Visor: All Technical Service Bulletins Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Bulletin No.: 06-08-42-002A Date: January 23, 2007 TECHNICAL Subject: Sunshade (Visor) Vanity Mirror Bulb Inoperative (Replace Vanity Mirror Bulb Only) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2005-2007 Cadillac STS 2001-2005 Chevrolet Impala, Monte Carlo 2001-2006 Chevrolet Silverado Crew Cab, Suburban, Tahoe 2001-2006 GMC Sierra Crew Cab, Yukon, Yukon XL 2004-2005 Pontiac Grand Prix 2006-2007 HUMMER H3 Supercede: This bulletin is being updated to add the 2007 model year. Please discard Corporate Bulletin Number 06-08-42-002 (Section 08 - Body & Accessories). Condition Some customers may comment that a sunshade (visor) vanity mirror bulb is inoperative. Cause This condition may be caused by an inoperative bulb. Correction Do NOT replace the entire sunshade (visor) assembly. Replace the sunshade (visor) vanity mirror bulb with P/N 9442395 if repairing one of the affected models covered for an inoperative vanity mirror bulb. Refer to Vanity Mirror Lamp Replacement in SI. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sun Visor: > 06-08-42-002A > Jan > 07 > Interior Lighting Sun Visor Vanity Mirror Lamp Inop. > Page 9937 The vanity mirror bulb can be accessed by removing the lens. Place a flat-bladed tool in the notches and gently pry out the lens. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Procedures Sun Visor: Procedures SUNSHADE REPLACEMENT REMOVAL PROCEDURE The sunshades can be equipped with an illuminated vanity mirror. The illuminated vanity mirror is not serviced as a separate unit. 1. Position the sunshade so the bottom edge is pointing straight down. 2. Remove the sunshade from the sunshade anchor and position the sunshade between the sunshade anchor and the windshield. 3. Remove the screws from the sunshade. 4. Once the retainer shaft releases the sunshade will begin to separate from the bezel. Some back-and-forth movement may be necessary to release sunshade from the retainer. 5. Disconnect the electrical connector from the sunshade if equipped. 6. Remove the sunshade from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical to the sunshade connector if equipped. 2. Position the sunshade to the mounting point at the roof. 3. Position the sunshade just behind the sunshade anchor. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the sunshade screws. Tighten Tighten the sunshade screws to 2 N.m (18 lb in). 5. Position the sunshade into the sunshade anchor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Procedures > Page 9940 Sun Visor: Removal and Replacement Sunshade Replacement Sunshade Replacement Removal Procedure The sunshades can be equipped with an illuminated vanity mirror. The illuminated vanity mirror is not serviced as a separate unit. 1. Position the sunshade so the bottom edge is pointing straight down. 2. Remove the sunshade from the sunshade anchor and position the sunshade between the sunshade anchor and the windshield. 3. Remove the screws from the sunshade. 4. Once the retainer shaft releases the sunshade will begin to separate from the bezel. Some back-and-forth movement may be necessary to release sunshade from the retainer. 5. Disconnect the electrical connector from the sunshade if equipped. 6. Remove the sunshade from the vehicle. Installation Procedure 1. Connect the electrical to the sunshade connector if equipped. 2. Position the sunshade to the mounting point at the roof. 3. Position the sunshade just behind the sunshade anchor. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the sunshade screws. Tighten the sunshade screws to 2 N.m (18 lb in). 5. Position the sunshade into the sunshade anchor. Sunshade Anchor Replacement Sunshade Anchor Replacement Removal Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Sun Visor > Component Information > Service and Repair > Procedures > Page 9941 1. Unhook the sunshade from the sunshade anchor. 2. Remove the screw from the sunshade anchor. 3. Remove the sunshade anchor from the roof. Installation Procedure 1. Position the sunshade anchor to the mounting position in the roof. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screw to the sunroof anchor. Tighten the sunroof anchor screw to 3 N.m (27 lb in). 3. Reposition the sunshade to the original position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear Trim Panel: Service and Repair Compartment Trim Panel Replacement - Rear Compartment Trim Panel Replacement - Rear Removal Procedure 1. Open the rear compartment. 2. If equipped, remove the sill plate. Refer to Compartment Sill Plate Replacement - Rear. 3. If the vehicle is not equipped with a sill plate, remove the push-in retainers beside the lock striker. 4. Remove the convenience net and retainers, if equipped. 5. Remove the tail lamp retainers. 6. If equipped, remove the plastic cover from the On-Star module. 7. Remove the nuts from the module bracket. 8. Lift the module off the studs. 9. Disconnect the cellular antenna cable from the communication interface module by pulling outward on the square plastic housing. 10. Disconnect the two lower connectors from the module. 11. Disconnect the GPS antenna cable from the module by pulling outward on the circular metal sleeve. 12. Remove the module and the bracket from the rear compartment. 13. Remove the spare tire cover from the rear compartment. 14. Remove the seat back. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9946 15. From behind the seat back, remove the push-in retainers from the trim panel. 16. Pull back the trim panel from the rear seating area. 17. Remove the right, then the left trim panels from the rear compartment. Installation Procedure Important: The left trim panel goes under the right side. Install the left panel first. 1. Position the trim panels in the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9947 2. Return the trim panels to the installed position. 3. Press the trim over the rear shock tower studs. 4. Install the push-in retainers in the trim panels. 5. Install the spare tire cover to the rear compartment. 6. Install the rear seat back. 7. If equipped, position the communication interface module and the bracket in the rear compartment. 8. Connect the GPS antenna cable by pushing in on the metal sleeve. 9. Connect the two lower connectors to the module. 10. Connect the cellular antenna by pressing in on the square plastic housing. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9948 Notice: Refer to Fastener Notice in Service Precautions. 11. Install the nuts to the interface module bracket. Tighten the nuts to 4 N.m (35 lb in). 12. Install the plastic cover on the On-Star module. 13. Install the convenience net and retainers, if equipped. 14. Install the tail lamp retainers. 15. If equipped, install the sill plate. Refer to Compartment Sill Plate Replacement - Rear. 16. If the vehicle is not equipped with a sill plate, install the push-in retainers beside the lock striker. 17. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9949 Trim Panel: Service and Repair Garnish Molding Replacement GARNISH MOLDING REPLACEMENT - WINDSHIELD PILLAR (IMPALA) REMOVAL PROCEDURE 1. Remove the windshield garnish molding from the clip retainers on the upper side rail. 2. Slide the roof leg of the garnish molding out from under the center pillar trim panel. 3. Remove the garnish molding from the windshield pillar. 4. Remove the garnish molding lower leg from the front door carpet retainer by pulling up and back. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9950 5. Remove the windshield garnish molding. 6. If the clip retainer was damaged during the removal of the windshield garnish molding, remove the screw and the retainer from the upper side rail. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. 1. Install a new clip retainer to the upper side rail, if necessary. Tighten Tighten the retainer screw to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9951 2. Align the garnish molding lower leg to the front door carpet retainer and to the front door weatherstrip. 3. Align the garnish molding to the trough on the upper instrument panel trim panel. 4. Align the garnish molding retainers to the windshield pillar. 5. Slide the roof leg under the center pillar trim panel. 6. Align the garnish molding to the clip retainers on the upper side rail. 7. Install the garnish molding, applying pressure at all the retainers until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9952 Trim Panel: Service and Repair Trim Panel Replacement - Front Seat TRIM PANEL REPLACEMENT - FRONT SEAT REMOVAL PROCEDURE 1. Remove the front seat back recliner handle, using a small, flat-bladed tool. 2. Remove the front seat lumbar knob by pulling it off. 3. Remove the screw from the rear of the front seat cushion trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9953 4. Use a small, flat-bladed tool to remove the push-in retainer from the front of the front seat cushion trim panel. 5. Pull off the front seat cushion trim panel to release the two retaining clips located on each side the recliner handle hole. 6. Remove the power seat switch from the front seat cushion trim panel, if equipped. 7. Remove the heated seat switch from the front seat cushion trim panel, if equipped. 8. Remove the lumbar control switch from the front seat cushion trim panel, if equipped. 9. Remove the front seat cushion trim panel from the vehicle. INSTALLATION PROCEDURE 1. Install the power seat switch to the front seat cushion trim panel, if equipped. 2. Install the lumbar control switch to the front seat cushion trim panel, if equipped. 3. Install the heated seat switch to the front seat cushion trim panel, if equipped. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9954 4. Install the seat cushion trim panel, pressing in until the two retaining clips are fully seated. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the front cushion trim panel rear screws. Tighten Tighten the front seat cushion trim panel screws to 3 N.m (27 lb in). 6. Install the push-in retainer to the front of the front seat cushion trim panel, pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9955 7. Install the front seat lumbar knob, pressing into place until fully seated. 8. Install the front seat back recliner handle, pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9956 Trim Panel: Service and Repair Trim Panel Replacement - Lower Center Pillar TRIM PANEL REPLACEMENT - LOWER CENTER PILLAR (IMPALA) REMOVAL PROCEDURE 1. Remove the front carpet retainer. 2. Pull up the carpet retaining leg of the quarter lower trim panel as needed. 3. Pull the center pillar lower trim panel out to disengage the push-in retaining clips. 4. Slide the panel down, then out from under the upper trim panel. 5. Remove the seat belt from the slot in the center lower trim panel. 6. Remove the center lower trim panel from the center pillar. INSTALLATION PROCEDURE 1. Install the seat belt to the slot into the center lower trim panel. 2. Align the center lower trim panel to the center pillar. 3. Slide the panel under the upper trim panel. 4. Install the push-in retaining clips to the center lower trim panel. Press firmly on the clips until fully seated. 5. Install the carpet retaining leg to the quarter lower trim panel. 6. Install the front carpet retainer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9957 Trim Panel: Service and Repair Compartment Trim Panel Replacement - Rear Compartment Trim Panel Replacement - Rear Removal Procedure 1. Open the rear compartment. 2. If equipped, remove the sill plate. Refer to Compartment Sill Plate Replacement - Rear. 3. If the vehicle is not equipped with a sill plate, remove the push-in retainers beside the lock striker. 4. Remove the convenience net and retainers, if equipped. 5. Remove the tail lamp retainers. 6. If equipped, remove the plastic cover from the On-Star module. 7. Remove the nuts from the module bracket. 8. Lift the module off the studs. 9. Disconnect the cellular antenna cable from the communication interface module by pulling outward on the square plastic housing. 10. Disconnect the two lower connectors from the module. 11. Disconnect the GPS antenna cable from the module by pulling outward on the circular metal sleeve. 12. Remove the module and the bracket from the rear compartment. 13. Remove the spare tire cover from the rear compartment. 14. Remove the seat back. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9958 15. From behind the seat back, remove the push-in retainers from the trim panel. 16. Pull back the trim panel from the rear seating area. 17. Remove the right, then the left trim panels from the rear compartment. Installation Procedure Important: The left trim panel goes under the right side. Install the left panel first. 1. Position the trim panels in the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9959 2. Return the trim panels to the installed position. 3. Press the trim over the rear shock tower studs. 4. Install the push-in retainers in the trim panels. 5. Install the spare tire cover to the rear compartment. 6. Install the rear seat back. 7. If equipped, position the communication interface module and the bracket in the rear compartment. 8. Connect the GPS antenna cable by pushing in on the metal sleeve. 9. Connect the two lower connectors to the module. 10. Connect the cellular antenna by pressing in on the square plastic housing. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9960 Notice: Refer to Fastener Notice in Service Precautions. 11. Install the nuts to the interface module bracket. Tighten the nuts to 4 N.m (35 lb in). 12. Install the plastic cover on the On-Star module. 13. Install the convenience net and retainers, if equipped. 14. Install the tail lamp retainers. 15. If equipped, install the sill plate. Refer to Compartment Sill Plate Replacement - Rear. 16. If the vehicle is not equipped with a sill plate, install the push-in retainers beside the lock striker. 17. Close the rear compartment. Garnish Molding Replacement GARNISH MOLDING REPLACEMENT - WINDSHIELD PILLAR (IMPALA) REMOVAL PROCEDURE 1. Remove the windshield garnish molding from the clip retainers on the upper side rail. 2. Slide the roof leg of the garnish molding out from under the center pillar trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9961 3. Remove the garnish molding from the windshield pillar. 4. Remove the garnish molding lower leg from the front door carpet retainer by pulling up and back. 5. Remove the windshield garnish molding. 6. If the clip retainer was damaged during the removal of the windshield garnish molding, remove the screw and the retainer from the upper side rail. INSTALLATION PROCEDURE NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9962 1. Install a new clip retainer to the upper side rail, if necessary. Tighten Tighten the retainer screw to 2 N.m (18 lb in). 2. Align the garnish molding lower leg to the front door carpet retainer and to the front door weatherstrip. 3. Align the garnish molding to the trough on the upper instrument panel trim panel. 4. Align the garnish molding retainers to the windshield pillar. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9963 5. Slide the roof leg under the center pillar trim panel. 6. Align the garnish molding to the clip retainers on the upper side rail. 7. Install the garnish molding, applying pressure at all the retainers until fully seated. Trim Panel Replacement - Front Seat TRIM PANEL REPLACEMENT - FRONT SEAT REMOVAL PROCEDURE 1. Remove the front seat back recliner handle, using a small, flat-bladed tool. 2. Remove the front seat lumbar knob by pulling it off. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9964 3. Remove the screw from the rear of the front seat cushion trim panel. 4. Use a small, flat-bladed tool to remove the push-in retainer from the front of the front seat cushion trim panel. 5. Pull off the front seat cushion trim panel to release the two retaining clips located on each side the recliner handle hole. 6. Remove the power seat switch from the front seat cushion trim panel, if equipped. 7. Remove the heated seat switch from the front seat cushion trim panel, if equipped. 8. Remove the lumbar control switch from the front seat cushion trim panel, if equipped. 9. Remove the front seat cushion trim panel from the vehicle. INSTALLATION PROCEDURE 1. Install the power seat switch to the front seat cushion trim panel, if equipped. 2. Install the lumbar control switch to the front seat cushion trim panel, if equipped. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9965 3. Install the heated seat switch to the front seat cushion trim panel, if equipped. 4. Install the seat cushion trim panel, pressing in until the two retaining clips are fully seated. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the front cushion trim panel rear screws. Tighten Tighten the front seat cushion trim panel screws to 3 N.m (27 lb in). 6. Install the push-in retainer to the front of the front seat cushion trim panel, pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9966 7. Install the front seat lumbar knob, pressing into place until fully seated. 8. Install the front seat back recliner handle, pressing into place until fully seated. Trim Panel Replacement - Lower Center Pillar TRIM PANEL REPLACEMENT - LOWER CENTER PILLAR (IMPALA) REMOVAL PROCEDURE 1. Remove the front carpet retainer. 2. Pull up the carpet retaining leg of the quarter lower trim panel as needed. 3. Pull the center pillar lower trim panel out to disengage the push-in retaining clips. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9967 4. Slide the panel down, then out from under the upper trim panel. 5. Remove the seat belt from the slot in the center lower trim panel. 6. Remove the center lower trim panel from the center pillar. INSTALLATION PROCEDURE 1. Install the seat belt to the slot into the center lower trim panel. 2. Align the center lower trim panel to the center pillar. 3. Slide the panel under the upper trim panel. 4. Install the push-in retaining clips to the center lower trim panel. Press firmly on the clips until fully seated. 5. Install the carpet retaining leg to the quarter lower trim panel. 6. Install the front carpet retainer. Trim Panel Replacement - Lower Center Pillar (Impala) Trim Panel Replacement - Lower Center Pillar (Impala) Removal Procedure 1. Remove the front carpet retainer. 2. Pull up the carpet retaining leg of the quarter lower trim panel as needed. 3. Pull the center pillar lower trim panel out to disengage the push-in retaining clips. 4. Slide the panel down, then out from under the upper trim panel. 5. Remove the seat belt from the slot in the center lower trim panel. 6. Remove the center lower trim panel from the center pillar. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9968 1. Install the seat belt to the slot into the center lower trim panel. 2. Align the center lower trim panel to the center pillar. 3. Slide the panel under the upper trim panel. 4. Install the push-in retaining clips to the center lower trim panel. Press firmly on the clips until fully seated. 5. Install the carpet retaining leg to the quarter lower trim panel. 6. Install the front carpet retainer. Trim Panel Replacement - Rear Quarter Lower TRIM PANEL REPLACEMENT - REAR QUARTER LOWER (IMPALA) REMOVAL PROCEDURE 1. Remove the rear seat cushion. 2. Remove the rear seat back. 3. Pull out on the rear quarter upper trim panel to disengage the lower connector. Refer to Trim Panel Replacement - Rear Quarter Upper (Impala)Trim Panel Replacement - Rear Quarter Upper (Monte Carlo). 4. Pull up to disengage the carpet retainer leg clip and out to disengage the quarter panel clips. 5. Slide the panel down and out from under the quarter upper panel. 6. Remove the rear quarter lower trim panel from the vehicle. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9969 1. Align the rear quarter lower trim panel push-in retainers to the rear quarter inner lower panel and to the rear door weatherstripping. 2. Install the rear quarter lower trim panel by applying pressure to secure at all push-in retainers locations. 3. Install the quarter upper trim panel. 4. Install the rear seat back. 5. Install the rear seat cushion. Trim Panel Replacement - Rear Quarter Lower (Impala) Trim Panel Replacement - Rear Quarter Lower (Impala) Removal Procedure 1. Remove the rear seat cushion. 2. Remove the rear seat back. 3. Pull out on the rear quarter upper trim panel to disengage the lower connector. Refer to Trim Panel Replacement - Rear Quarter Upper (Impala) Trim Panel Replacement - Rear Quarter Upper (Monte Carlo). 4. Pull up to disengage the carpet retainer leg clip and out to disengage the quarter panel clips. 5. Slide the panel down and out from under the quarter upper panel. 6. Remove the rear quarter lower trim panel from the vehicle. Installation Procedure 1. Align the rear quarter lower trim panel push-in retainers to the rear quarter inner lower panel and to the rear door weatherstripping. 2. Install the rear quarter lower trim panel by applying pressure to secure at all push-in retainers locations. 3. Install the quarter upper trim panel. 4. Install the rear seat back. 5. Install the rear seat cushion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9970 Trim Panel Replacement - Rear Quarter Upper TRIM PANEL REPLACEMENT - REAR QUARTER UPPER (IMPALA) REMOVAL PROCEDURE 1. Remove the rear seat back. 2. Reposition the rear seat belt from the trim panel. 3. Pull down on the trim panel to disengage the clip retainers on the roof side rail. 4. Pull out to disengage the clips located at the bottom of the triangular window. 5. Slide the roof leg out from under the upper trim panel of the center pillar. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9971 6. Remove the rear quarter upper trim panel from the rear quarter upper inner panel. 7. Remove the rear quarter upper trim panel from the vehicle. INSTALLATION PROCEDURE 1. Install a new dual-lock retainer to the rear quarter inner panel, if required. 2. Slide the roof leg under the upper trim panel of the center pillar. 3. Reposition the rear seat belt to the trim panel. 4. Align the push-in retainers from the trim panel with the slots by the triangular window. 5. Install the trim panel push-in retainers by applying pressure to secure all of the push-in retainer locations. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9972 6. Align the trim panel to the clip retainers on the roof side rail. 7. Install the trim panel by applying upward pressure to the retainer locations until fully seated. 8. Install the rear seat back. Trim Panel Replacement - Rear Quarter Upper (Impala) Trim Panel Replacement - Rear Quarter Upper (Impala) Removal Procedure 1. Remove the rear seat back. 2. Reposition the rear seat belt from the trim panel. 3. Pull down on the trim panel to disengage the clip retainers on the roof side rail. 4. Pull out to disengage the clips located at the bottom of the triangular window. 5. Slide the roof leg out from under the upper trim panel of the center pillar. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9973 6. Remove the rear quarter upper trim panel from the rear quarter upper inner panel. 7. Remove the rear quarter upper trim panel from the vehicle. Installation Procedure 1. Install a new dual-lock retainer to the rear quarter inner panel, if required. 2. Slide the roof leg under the upper trim panel of the center pillar. 3. Reposition the rear seat belt to the trim panel. 4. Align the push-in retainers from the trim panel with the slots by the triangular window. 5. Install the trim panel push-in retainers by applying pressure to secure all of the push-in retainer locations. 6. Align the trim panel to the clip retainers on the roof side rail. 7. Install the trim panel by applying upward pressure to the retainer locations until fully seated. 8. Install the rear seat back. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9974 Trim Panel Replacement - Rear Window Shelf TRIM PANEL REPLACEMENT - REAR WINDOW SHELF (IMPALA) REMOVAL PROCEDURE 1. Remove the rear seat cushion. 2. Remove the rear seat back. 3. Remove the rear upper quarter trim panel. 4. Remove the push-in retainers from the front of the rear window trim panel. 5. Lift the rear window trim panel and remove the seat belts through the slots in the rear window trim panel. 6. Slide the rear window trim panel forward to disengage the integral hook from the retaining hole and remove the rear window trim panel. INSTALLATION PROCEDURE 1. Slide the rear window trim panel rearward to engage the integral hook in the retaining hole. 2. Lift the rear window trim panel and route the seat belts through the slots in the rear window trim panel. 3. Install the push-in retainers to the front edge of the rear window trim panel. 4. Install the rear quarter upper trim panel. 5. Install the rear seat back. 6. Install the rear seat cushion. Trim Panel Replacement - Rear Window Shelf (Impala) Trim Panel Replacement - Rear Window Shelf (Impala) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9975 Removal Procedure 1. Remove the rear seat cushion. 2. Remove the rear seat back. 3. Remove the rear upper quarter trim panel. 4. Remove the push-in retainers from the front of the rear window trim panel. 5. Lift the rear window trim panel and remove the seat belts through the slots in the rear window trim panel. 6. Slide the rear window trim panel forward to disengage the integral hook from the retaining hole and remove the rear window trim panel. Installation Procedure 1. Slide the rear window trim panel rearward to engage the integral hook in the retaining hole. 2. Lift the rear window trim panel and route the seat belts through the slots in the rear window trim panel. 3. Install the push-in retainers to the front edge of the rear window trim panel. 4. Install the rear quarter upper trim panel. 5. Install the rear seat back. 6. Install the rear seat cushion. Trim Panel Replacement - Upper Center Pillar TRIM PANEL REPLACEMENT - UPPER CENTER PILLAR (IMPALA) REMOVAL PROCEDURE 1. Remove the upper seat belt guide loop attachment from the adjuster bracket. - For the left front, refer to Seat Belt Retractor Replacement - Left Front (Impala)Seat Belt Retractor Replacement - Left Front (Monte Carlo) in Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9976 Seat Belts. - for the right front, refer to Seat Belt Retractor Replacement - Right Front (Impala)Seat Belt Retractor Replacement - Right Front (Monte Carlo) in Seat Belts. 2. Pull out on the panel to disengage the retainer clip. 3. Remove the upper center pillar trim panel from the center pillar. INSTALLATION PROCEDURE 1. Align the upper center pillar trim panel to the center pillar. 2. Install the upper center pillar trim panel by applying sufficed pressure engage the push-in retainers. 3. Install the upper seat belt upper guide loop attachment to the adjuster bracket. - For the left front, refer to Seat Belt Retractor Replacement - Left Front (Impala)Seat Belt Retractor Replacement - Left Front (Monte Carlo) in Seat Belts. - For the right front, refer to Seat Belt Retractor Replacement - Right Front (Impala)Seat Belt Retractor Replacement - Right Front (Monte Carlo) in Seat Belts. Trim Panel Replacement - Upper Center Pillar (Impala) Trim Panel Replacement - Upper Center Pillar (Impala) Removal Procedure 1. Remove the upper seat belt guide loop attachment from the adjuster bracket. * For the left front, refer to Seat Belt Retractor Replacement - Left Front (Impala) Seat Belt Retractor Replacement - Left Front (Monte Carlo) in Seat Belts. * for the right front, refer to Seat Belt Retractor Replacement - Right Front (Impala) Seat Belt Retractor Replacement - Right Front (Monte Carlo) in Seat Belts. 2. Pull out on the panel to disengage the retainer clip. 3. Remove the upper center pillar trim panel from the center pillar. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair > Compartment Trim Panel Replacement - Rear > Page 9977 1. Align the upper center pillar trim panel to the center pillar. 2. Install the upper center pillar trim panel by applying sufficed pressure engage the push-in retainers. 3. Install the upper seat belt upper guide loop attachment to the adjuster bracket. * For the left front, refer to Seat Belt Retractor Replacement - Left Front (Impala) Seat Belt Retractor Replacement - Left Front (Monte Carlo) in Seat Belts. * for the right front, refer to Seat Belt Retractor Replacement - Right Front (Impala) Seat Belt Retractor Replacement - Right Front (Monte Carlo) in Seat Belts. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Procedures Door Lock Cylinder: Procedures Frozen Lock Cylinder Repair The frozen lock cylinders due to the cold weather may be repaired using the following procedure: 1. Apply heat to the cylinder area with a heat gun. 2. Hold the shutter door open with a paper clip or similar item and force air into the cylinder using compressed air and a blow gun attachment. 3. While holding the shutter door open inject a small amount of multi-purpose lubricant GM P/N 12346241 or equivalent. 4. Work the key into the cylinder several times and wipe any excess lubrication residue from the key. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder > Component Information > Service and Repair > Procedures > Page 9984 Door Lock Cylinder: Removal and Replacement Lock Cylinder Replacement - Door (Impala) Removal Procedure Important: Do not attempt repairs in order to correct lock cylinder discrepancies. Replace the lock cylinder. 1. Remove the front door outside handle. 2. Remove the lock cylinder retainer clip. 3. Remove the lock cylinder from the front door outside door handle. Installation Procedure 1. Install the lock cylinder to the front door outside door handle. 2. Install the lock cylinder retainer clip. 3. Install the front door outside handle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Diagrams Door Lock Cylinder Switch: Diagrams Door Lock Cylinder Switch-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Door Locks > Door Lock Cylinder Switch > Component Information > Diagrams > Page 9988 Door Lock Cylinder Switch-Front Passenger (If Equipped) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information Key: Technical Service Bulletins Locks - Key Code Security Rules and Information INFORMATION Bulletin No.: 10-00-89-010 Date: May 27, 2010 Subject: Key Code Security Rules and Information on GM KeyCode Look-Up Application (Canada Only) Models: 2011 and Prior GM Passenger Cars and Trucks 2010 and Prior HUMMER H2, H3 2009 and Prior Saturn and Saab 2002 and Prior Isuzu Attention: This bulletin has been created to address potential issues and questions regarding KeyCode security. This bulletin should be read by all parties involved in KeyCode activity, including dealer operator, partner security coordinator, sales, service and parts departments. A copy of this bulletin should be printed and maintained in the parts department for use as a reference. Important U.S. dealers should refer to Corporate Bulletin Number 10-00-89-009. Where Are Key Codes Located? General Motors provides access to KeyCodes through three sources when a vehicle is delivered to a dealer. Vehicle KeyCodes are located on the original vehicle invoice to the dealership. There is a small white bar coded tag sent with most new vehicles that also has the key code printed on it. Dealerships should make a practice of comparing the tag's keycode numbers to the keycode listed on the invoice. Any discrepancy should be reported immediately to the GM of Canada Key Code Inquiry Desk. Remember to remove the key tag prior to showing vehicles to potential customers. The third source for Key codes is through the GM KeyCode Look-Up feature within the OEConnection D2DLink application. KeyCode Look-Up currently goes back 17 previous model years from the current model year. When a vehicle is received by the dealership, care should be taken to safeguard the original vehicle invoice and KeyCode tag provided with the vehicle. Potential customers should not have access to the invoice or this KeyCode tag prior to the sale being completed. After a sale has been completed, the KeyCode information belongs to the customer and General Motors. Tip Only the original invoice contains key code information, a re-printed invoice does not. GM KeyCode Look-Up Application for GM of Canada Dealers All dealers should review the General Motors of Canada KeyCode Look-Up Policies and Procedures (Service Policy & Procedures Manual Section 3.1.6 "Replacement of VIN plates & keys"). Please note that the KeyCode Access site is restricted. Only authorized users should be using this application. Please see your Parts Manager for site authorized users. KeyCode Look-Up currently goes back 17 years from current model year. Important notes about security: - Users may not access the system from multiple computers simultaneously. - Users may only request one KeyCode at a time. - KeyCode information will only be available on the screen for 2 minutes. - Each user is personally responsible for maintaining and protecting their password. - Never share your password with others. - User Id's are suspended after 6 consecutive failed attempts. - User Id's are disabled if not used for 90 days. - Processes must be in place for regular dealership reviews. - The Parts Manager (or assigned management) must have processes in place for employee termination or life change events. Upon termination individuals access must be turned off immediately and access should be re-evaluated upon any position changes within the dealership. - If you think your password or ID security has been breached, contact Dealer Systems Support at 1-800-265-0573. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 9993 Each user will be required to accept the following agreement each time the KeyCode application is used. Key Code User Agreement - Key codes are proprietary information belonging to General Motors Corporation and to the vehicle owner. - Unauthorized access to, or use of, key code information is unlawful and may subject the user to criminal and civil penalties. - This information should be treated as strictly confidential and should not be disclosed to anyone unless authorized. I will ensure that the following information is obtained prior to releasing any Key Code information: 1. Government issued picture ID (Drivers License) 2. Registration or other proof of ownership. Registration should have normal markings from the Province that issued the registration and possibly the receipt for payment recorded as well. Important - GM takes this agreement seriously. Each user must be certain of vehicle ownership before giving out key codes. - When the ownership of the vehicle is in doubt, dealership personnel should not provide the information. Key code requests should never be received via a fax or the internet and key codes should never be provided to anyone in this manner. A face to face contact with the owner of the vehicle is the expected manner that dealers will use to release a key code or as otherwise stipulated in this bulletin or other materials. - Key codes should NEVER be sent via a fax or the internet. - Each Dealership should create a permanent file to document all KeyCode Look Up transactions. Requests should be filed by VIN and in each folder retain copies of the following: - Government issued picture ID (Drivers License) - Registration or other proof of ownership. - Copy of the paid customer receipt which has the name of the employee who cut and sold the key to the customer. - Do not put yourself or your Dealership in the position of needing to "explain" a KeyCode Look Up to either GM or law enforcement officials. - Dealership Management has the ability to review all KeyCode Look-Up transactions. - Dealership KeyCode documentation must be retained for two years. Frequently Asked Questions (FAQs) for GM of Canada Dealers How do I request a KeyCode for customer owned vehicle that is not registered? Scrapped, salvaged or stored vehicles that do not have a current registration should still have the ownership verified by requesting the vehicle title, current insurance policy and / or current lien holder information from the customers financing source. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. In these cases, a short description of the vehicle (scrapped, salvaged, etc.) and the dealership location should be kept on file. Any clarifying explanation should be entered into the comments field. How do I document a KeyCode request for a vehicle that is being repossessed? The repossessor must document ownership of the vehicle by providing a court ordered repossession order and lien-holder documents prior to providing key code information. Copies of the repossessors Drivers License and a business card should be retained by the dealership for documentation. What do I do if the registration information is locked in the vehicle? Every effort should be made to obtain complete information for each request. Each Dealership will have to decide on a case by case basis if enough information is available to verify the customer's ownership of the vehicle. Other forms of documentation include vehicle title, insurance policy, and or current lien information from the customers financing source. Dealership Management must be involved in any request without complete information. If you cannot determine if the customer is the owner of the vehicle, do not provide the key code information. Can I get a print out of the information on the screen? It is important to note that the Key Code Look Up Search Results contain sensitive and/or proprietary information. For this reason GM recommends against printing it. If the Search Results must be printed, store and/or dispose of the printed copy properly to minimize the risk of improper or illegal use. Who in the dealership has access to the KeyCode application? Dealership Parts Manager (or assigned management) will determine, and control, who is authorized to access the KeyCode Look Up application. However, we anticipate that dealership parts and service management will be the primary users of the application. The KeyCode Look Up application automatically tracks each user activity session. Information tracked by the system includes: User name, User ID, all other entered data and the date/time of access. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 9994 What if I input the VIN incorrectly? If an incorrect VIN is entered into the system (meaning that the system does not recognize the VIN or that the VIN has been entered incorrectly) the system will return an error message. If I am an authorized user for the KeyCode application, can I access the application from home? Yes. What if I suspect key code misuse? Your dealership should communicate the proper procedures for requesting key codes. Any suspicious activity either within the dealership or externally should be reported to Dealer Systems Support at 1-800-265-0573 or GM of Canada Key Code Inquiry Desk at 1-905-644-4892. Whose key codes can I access through the system? At this time the following Canadian vehicle codes are available through the system: Chevrolet, Cadillac, Buick, Pontiac, GMC, HUMMER (H2 and H3 only), Oldsmobile, Saturn, Saab and Isuzu (up to 2002 model year) for a maximum of 17 model years. What should I do if I enter a valid VIN and the system does not produce any key code information? Occasionally, the KeyCode Look Up application may not produce a key code for a valid VIN. This may be the result of new vehicle information not yet available. In addition, older vehicle information may have been sent to an archive status. If you do not receive a key code returned for valid VIN, you should contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. How do I access KeyCodes if the KeyCode Look-up system is down? If the KeyCode Look-up system is temporarily unavailable, you can contact the original selling dealer who may have it on file or contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the customer is dealing with an emergency lock-out situation, you need to have the customer contact Roadside assistance, OnStar if subscribed, or 911. What should I do if the KeyCode from the look-up system does not work on the vehicle? On occasion a dealer may encounter a KeyCode that will not work on the vehicle in question. In cases where the KeyCode won't work you will need to verify with the manufacturer of the cutting equipment that the key has been cut correctly. If the key has been cut correctly you may be able to verify the proper KeyCode was given through the original selling dealer. When unable to verify the KeyCode through the original selling dealer contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. If the key has been cut correctly and the code given does not work, the lock cylinder may have been changed. In these situations following the proper SI document for recoding a key or replacing the lock cylinder may be necessary. How long do I have to keep KeyCode Records? Dealership KeyCode documentation must be retained for two years. Can I get a KeyCode changed in the Look-Up system? Yes, KeyCodes can be changed in the Look-Up system if a lock cylinder has been changed. Contact GM of Canada Key Code Inquiry Desk at 1-905-644-4892. What information do I need before I can provide a driver of a company fleet vehicle Keys or KeyCode information? The dealership should have a copy of the individual's driver's license, proof of employment and registration. If there is any question as to the customer's employment by the fleet company, the dealer should attempt to contact the fleet company for verification. If there is not enough information to determine ownership and employment, this information should not be provided. How do I document a request from an Independent Repair facility for a KeyCode or Key? The independent must provide a copy of their driver's license, proof of employment and signed copy of the repair order for that repair facility. The repair order must include customer's name, address, VIN, city, province and license plate number. Copies of this information must be included in your dealer KeyCode file. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Key > Component Information > Technical Service Bulletins > Locks - Key Code Security Rules and Information > Page 9995 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Diagrams Remote Control Door Lock Receiver (RCDLR) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Receiver > Component Information > Diagrams > Page 10000 Keyless Entry Receiver: Service and Repair REMOTE CONTROL DOOR LOCK RECEIVER REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel (IP) upper trim panel. 2. Disengage the receiver retainers from the IP upper trim pad. 3. Disconnect the receiver electrical connector. 4. Remove the receiver. INSTALLATION PROCEDURE 1. Connect the electrical connector. 2. Engage the receiver retainers to the IP upper trim pad. 3. Install the IP upper trim panel. 4. If a new remote control door lock receiver is being installed, synchronize the transmitter. Refer to Transmitter Synchronization. See: Testing and Inspection/Programming and Relearning 5. If a new remote control door lock receiver is being installed, program the transmitter. Refer to Transmitter Programming. See: Testing and Inspection/Programming and Relearning Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Service and Repair Keyless Entry Transmitter Battery: Service and Repair TRANSMITTER BATTERY REPLACEMENT Under normal use, the battery in the remote control door lock transmitter will last about 2 years. The battery is weak if the transmitter does not work at the normal range in any location. If you have to get close to the vehicle before the transmitter works, change the battery. Removal Procedure 1. Insert a dime or a flat-bladed tool into the slot on the side of the transmitter in order to disassemble the transmitter. 2. Twist the dime or tool in order to separate the halves. 3. Remove the battery from the transmitter. Installation Procedure 1. Install the battery into the transmitter. 2. Reassemble the transmitter. 3. Ensure that the halves snap together tightly in order to prevent water intrusion. 4. Test for proper transmitter operation. Refer to Transmitter Programming. 5. Synchronize the transmitter, as needed. Refer to Transmitter Synchronization. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Diagrams Door Lock Cylinder Switch: Diagrams Door Lock Cylinder Switch-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Door Lock Cylinder Switch > Component Information > Diagrams > Page 10009 Door Lock Cylinder Switch-Front Passenger (If Equipped) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Procedures Power Door Lock Actuator: Procedures Lock Actuator Replacement - Front Door LOCK ACTUATOR REPLACEMENT - FRONT DOOR REMOVAL PROCEDURE 1. Remove the front door lock. 2. Remove the front door lock to front door lock actuator screws. 3. Remove the front door actuator from the front door lock. INSTALLATION PROCEDURE 1. Align the front door actuator to the front door lock. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the front door lock to front door actuator screws. Tighten Tighten the front door actuator screws to 2 N.m (18 lb in). 3. Install the front door lock. Lock Actuator Replacement - Rear Door LOCK ACTUATOR REPLACEMENT - REAR DOOR Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Procedures > Page 10014 REMOVAL PROCEDURE 1. Remove the rear door lock. 2. Remove the rear door lock to rear door lock actuator screws. 3. Remove the rear door actuator from the rear door lock. INSTALLATION PROCEDURE 1. Align the rear door actuator to the rear door lock. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear door lock to rear door actuator screws. Tighten Tighten the rear door actuator screws to 2 N.m (18 lb in). 3. Install the rear door lock. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Procedures > Page 10015 Power Door Lock Actuator: Removal and Replacement Lock Actuator Replacement - Front Door Lock Actuator Replacement - Front Door Removal Procedure 1. Remove the front door lock. 2. Remove the front door lock to front door lock actuator screws. 3. Remove the front door actuator from the front door lock. Installation Procedure 1. Align the front door actuator to the front door lock. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front door lock to front door actuator screws. Tighten the front door actuator screws to 2 N.m (18 lb in). 3. Install the front door lock. Lock Actuator Replacement - Rear Door Lock Actuator Replacement - Rear Door Removal Procedure 1. Remove the rear door lock. 2. Remove the rear door lock to rear door lock actuator screws. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Service and Repair > Procedures > Page 10016 3. Remove the rear door actuator from the rear door lock. Installation Procedure 1. Align the rear door actuator to the rear door lock. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the rear door lock to rear door actuator screws. Tighten the rear door actuator screws to 2 N.m (18 lb in). 3. Install the rear door lock. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations Front Door Trim-Typical Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 10020 Power Door Lock Switch: Diagrams Door Lock Switch-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 10021 Door Lock Switch-Front Passenger Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 10022 Power Door Lock Switch: Description and Operation POWER DOOR LOCK SWITCHES The power door lock switches are used to either arm or disarm the CTD system. Pressing the lock position will cause the CTD to arm after all doors are closed and the 30 second delay period has elapsed. Pressing the unlock position will disarm the CTD system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 10023 Power Door Lock Switch: Service and Repair POWER DOOR LOCK SWITCH REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Remove the inside door handle bezel. 2. Remove the power door lock switch from the inside door handle bezel using a small, flat-bladed tool in order to release the retainers. 3. Disconnect the electrical connector from the power door lock switch. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Locations > Page 10024 1. Install the power door lock switch to the inside door handle bezel pressing into place until fully seated. 2. Connect the electrical connector to the power door lock switch. 3. Install the inside door handle bezel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Service and Repair Trunk / Liftgate Lock Cylinder: Service and Repair Lock Cylinder Replacement - Rear Compartment Lid (Impala) Removal Procedure 1. Remove the rear compartment lid applique. 2. Drill out the 2 rivets from the rear compartment lock cylinder. 3. Remove the rear compartment lock cylinder and gasket from the rear compartment lid. Installation Procedure 1. Align the lock cylinder shaft to the rear compartment lid latch. 2. Align the rear compartment lock cylinder and gasket to the holes in the rear compartment lid, and press in until fully seated. 3. Install the rear compartment lock cylinder and gasket to the rear compartment lid using 2 rivets. 4. Install the rear compartment lid applique. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Technical Service Bulletins > Mirrors - Heated Mirrors, Defrosting Time Heated Element: Technical Service Bulletins Mirrors - Heated Mirrors, Defrosting Time INFORMATION Bulletin No.: 08-08-64-011A Date: February 25, 2010 Subject: Information on Heated Electrochromatic Outside Rearview Mirror Performance Models: 2010 and Prior GM Passenger Cars and Light Duty Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to update the model years. Please discard Corporate Bulletin Number 08-08-64-011 (Section 08 - Body and Accessories). Defrosting Time/Performance Concern The electrochromatic (auto-dimming) outside rearview mirror used on the driver's side of many GM vehicles is slower to defrost than the passenger side outside rearview mirror. This is a normal condition. The glass on the driver's side electrochromatic mirror is twice as thick as the traditional glass on the passenger side mirror. The heating elements for the mirrors on both sides draw the same wattage, therefore the driver's side mirror will take approximately twice as long to defrost as the passenger mirror (approximately four minutes versus two minutes). Should a customer indicate that the driver's side heated mirror is not functioning correctly, verify it's function based upon this information prior to replacing the mirror. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Description and Operation > Personalization Memory Positioning Systems: Description and Operation Personalization PERSONALIZATION DESCRIPTION AND OPERATION Personalization features may be set for the vehicle or the driver. Vehicle features do not change with each driver. Specific drivers are recognized by the vehicle through the keyless entry transmitters, the memory buttons, or the driver information center (DISC), and the personalization settings for that driver are recalled. For more information on vehicle personalization features for this vehicle, refer to Vehicle Personalization. This vehicle does not have specific driver personalization available. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 10037 Memory Positioning Systems: Description and Operation Driver Personalization DRIVER PERSONALIZATION PERSONAL CHOICE RADIO CONTROLS With this feature the vehicle will recall the latest radio settings as adjusted the last time the vehicle was operated. Perform the following steps in order to Personalize the Personal Choice Radio Controls feature: 1. Press the Unlock button on key fob 1. 2. Turn the ignition to Run. 3. Select and Set all of the following settings: - AM/FM presets - Last tuned station - Volume - Tone - Audio source; Radio, Cassette or CD 4. Turn ignition Off. Repeat this procedure using key fob 2 to program the desired settings for driver 2. ADDITIONAL INFORMATION Refer to Radio/Audio System Description and Operation in Radio, Stereo and Compact Disc for more information about the Personal Choice Radio Controls feature. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 10038 Memory Positioning Systems: Description and Operation Vehicle Personalization VEHICLE PERSONALIZATION PROGRAMMING FEATURES ENTER PROGRAMMING MODE Perform the following steps in order to enter the programming mode: 1. Press the DISP button on radio for at least 10 seconds. 2. Press the SEEK button to scroll through the menu. DELAYED HEADLAMP ILLUMINATION Continue with the following steps in order to personalize the delayed headlamp illumination feature: 1. Scroll through the menu, using the SEEK button, until LT. DELAY is displayed. 2. Press the DISP button to enter the menu. 3. Press the PREV or NEXT button to scroll through the following options: - DISABLED - 30 SEC - 60 SEC - RETURN 4. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. AUTOMATIC DOOR LOCKS Continue with the following steps in order to personalize the automatic door locks feature: 1. Scroll through the menu, using the SEEK button, until AUTOLOCK is displayed. 2. Press the DISP button to enter the menu. 3. Press the PREV or NEXT button to scroll through the following options: - OFF - LCK ONLY - DRVR UNL - ALL UNL 4. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. REMOTE ACTIVATION VERIFICATION Continue with the following steps in order to personalize the remote activation verification feature: 1. Scroll through the menu, using the SEEK button, until FOBLIGHT is displayed. 2. Press the DISP button to enter the menu. 3. Press the PREV or NEXT button to scroll through the following options: - OFF - ON 4. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. 5. Exit to the MAIN MENU. 6. Scroll through the menu, using the SEEK button, until FOBHORN is displayed. 7. Press the DISP button to enter the menu. 8. Press the PREV or NEXT button to scroll through the following options: - OFF - PARTIAL - FULL 9. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. CONTENT THEFT DETERRENT Continue with the following steps in order to personalize the content theft deterrent options: 1. Scroll through the menu, using the SEEK button, until ALARM is displayed. 2. Press the DISP button to enter the menu. 3. Press the PREV or NEXT button to scroll through the following options: - OFF - ON 4. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. 5. Exit to the MAIN MENU. 6. Scroll through the menu, using the SEEK button, until TRNKJAMB is displayed. 7. Press the DISP button to enter the menu. 8. Press the PREV or NEXT button to scroll through the following options: - OFF - ON 9. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 10039 HORN CHIRP TIMER Continue with the following steps in order to personalize the duration of the horn chirp when the remote keyless transmitter is used: 1. Scroll through the menu, using the SEEK button, until CHIRP is displayed. 2. Press the DISP button to enter the menu. 3. Press the PREV or NEXT button to scroll through the following options: - SHORT - Short Chirp (16 msec) - LONG - Long Chirp (32 msec) 4. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. EXIT PROGRAMMING Continue with the following steps in order to exit the programming mode: 1. Press the SEEK button to scroll to the end of the MAIN MENU until EXIT is displayed. 2. Press the DISP button to exit the MAIN MENU. PROGRAMMING FEATURES WITH THE TECH 2 To enter programming with the Tech 2, perform the following actions: 1. Install the scan tool. 2. Turn ON the ignition with the engine OFF. 3. Select the correct vehicle and model year. 4. Select Body. 5. Select Personalization. DELAYED HEADLAMP ILLUMINATION Continue with the following steps in order to program the Delayed Headlamp Illumination feature: 1. Select Set Options. 2. Select F0 for Delayed Headlamp Illumination mode. 3. Highlight the desired mode from the following choices: - Mode 1: OFF - Mode 2: 30 seconds - Mode 3: 60 seconds 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. AUTOMATIC DOOR LOCK Continue with the following steps in order to program the Automatic Door Lock feature: 1. Select Set Options. 2. Select F1 for Automatic Door Lock Mode. 3. Highlight the desired mode for the following choices: - OFF - ADL out of Park - Unlock Drivers Door Only - Unlock All Doors 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. REMOTE VISUAL VERIFICATION MODE Continue with the following steps in order to program the Remote Unlock Verification Mode: 1. Select Set Options. 2. Select F2 for Remote Visual Verification Mode. 3. Highlight the desired mode for the following choices: - OFF - ON 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. REMOTE AUDIBLE VERIFICATION MODE Continue with the following steps in order to program the Remote Audible Verification Mode: 1. Select Set Options. 2. Select F3 for Remote Audible Verification Mode. 3. Highlight the desired mode for the following choices: - OFF - PARTIAL Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 10040 - FULL - DRL and Horn 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. CONTENT THEFT DETERRENT Continue with the following steps in order to program the CTD (Content Theft Deterrent System): 1. Select Set Options. 2. Select F4 for CTD Program Mode. 3. Highlight the desired mode for the following choices: - OFF - ON 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. CTD SHOCK SENSOR Continue with the following steps in order to program the CTD Shock Sensor. 1. Select Set Options. 2. Select F5 for CTD Program Mode. 3. Highlight the desired mode for the following choices: - OFF - ON 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. CTD TRUNK SWITCH Continue with the following steps in order to program the CTD Trunk Switch. 1. Select Set Options. 2. Select F6 for CTD Program Mode. 3. Highlight the desired mode for the following choices: - OFF - ON 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. HORN CHIRP MODE Continue with the following steps in order to program the Horn Chirp Mode. 1. Select Set Options. 2. Select F7 for Horn Chirp Mode. 3. Highlight the desired mode for the following choices: - Short Chirp - Long Chirp 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. POLICE OPTION (RPO A98) Continue with the following steps in order to program the Police Option Mode: 1. Select Set Options. 2. Select F8 Police Option Mode. 3. Highlight the desired mode for the following choices: - NO - YES 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. TRAP ALERT SYSTEM Continue with the following steps in order to program the Trap Alert System: 1. Select Set Options. 2. Select F9 Trap Alert System. 3. Highlight the desired mode for the following choice: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 10041 4. ENABLE 5. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 6. Select Save Options. 7. Exit the menu. ADDITIONAL INFORMATION For more information about the personalization features, refer to one of the following description and operations: Refer to Content Theft Deterrent (CTD) Description and Operation in Theft Deterrent for more information about the content theft deterrent features. - Refer to Power Door Locks Description and Operation in Doors for more information about the automatic door lock feature. - Refer to Interior Lighting Systems Description and Operation in Lighting Systems for more information about the delayed headlamp illumination feature. - Refer to Keyless Entry System Description and Operation in Keyless Entry for more information about remote activation verification. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair > Procedures Power Mirror Motor: Procedures MOTOR REPLACEMENT - POWER MIRROR REMOVAL PROCEDURE 1. Remove the door trim panel. 2. Disconnect the electrical connector to the mirror wire harness. CAUTION: Refer to Eye Protection Caution in Service Precautions. 3. Remove the mirror face. 4. Remove the screws from the mirror motor. 5. Pull the motor electrical harness through the mirror housing. 6. Remove the motor from the mirror housing. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair > Procedures > Page 10046 1. Position the motor to the mirror housing. 2. Pull the motor electrical harness through to the inside door panel. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws to the mirror motor. Tighten Tighten the mirror motor screws to 10 N.m (89 lb in). 4. Install the mirror face to the mirror housing. 5. Connect the electrical connector to the mirror wire harness. 6. Check the operation of the mirror. 7. Install the door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair > Procedures > Page 10047 Power Mirror Motor: Removal and Replacement Motor Replacement - Power Mirror Removal Procedure 1. Remove the door trim panel. 2. Disconnect the electrical connector to the mirror wire harness. Caution: Refer to Eye Protection Caution in Service Precautions. 3. Remove the mirror face. 4. Remove the screws from the mirror motor. 5. Pull the motor electrical harness through the mirror housing. 6. Remove the motor from the mirror housing. Installation Procedure 1. Position the motor to the mirror housing. 2. Pull the motor electrical harness through to the inside door panel. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screws to the mirror motor. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Service and Repair > Procedures > Page 10048 Tighten the mirror motor screws to 10 N.m (89 lb in). 4. Install the mirror face to the mirror housing. 5. Connect the electrical connector to the mirror wire harness. 6. Check the operation of the mirror. 7. Install the door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Front Of Driver Door Trim (Mirrors) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 10052 Power Mirror Switch: Diagrams Outside Rearview Mirror Switch Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations > Page 10053 Outside Rearview Mirror Switch Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Procedures Power Mirror Switch: Procedures POWER MIRROR SWITCH REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Remove the front door pull cup from the front door inner trim panel. 2. Disconnect the electrical connectors from the power mirror switch. 3. Remove the power mirror switch from the front door pull cup, using a small flat-bladed tool at the side of the mirror switch in order to release the mirror control switch retainer. 4. Remove the power mirror switch from the front door pull cup. INSTALLATION PROCEDURE 1. Install the power mirror switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the power mirror switch. 3. Install the front door pull cup to the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and Repair > Procedures > Page 10056 Power Mirror Switch: Removal and Replacement Power Mirror Switch Replacement (Impala) Removal Procedure 1. Remove the front door pull cup from the front door inner trim panel. 2. Disconnect the electrical connectors from the power mirror switch. 3. Remove the power mirror switch from the front door pull cup, using a small flat-bladed tool at the side of the mirror switch in order to release the mirror control switch retainer. 4. Remove the power mirror switch from the front door pull cup. Installation Procedure 1. Install the power mirror switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the power mirror switch. 3. Install the front door pull cup to the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: Customer Interest Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 10066 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint Paint: All Technical Service Bulletins Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 05-08-51-008C > Jun > 09 > Body - Bumps or Rust Colored Spots in Paint > Page 10072 Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 08-08-51-002 > Mar > 08 > Body - TPO Fascia Cleaning Prior to Painting Paint: All Technical Service Bulletins Body - TPO Fascia Cleaning Prior to Painting INFORMATION Bulletin No.: 08-08-51-002 Date: March 12, 2008 Subject: New Primer For TPO Fascias and Affected Cleaning Process of Painting Operation Models: 2009 and Prior Passenger Cars and Trucks 2009 and Prior HUMMER H2, H3 The purpose of this bulletin is to inform the technician that General Motors has made a change in the primer it uses for TPO plastic for service parts. This new primer comes in several different colors from five different suppliers. This change affects the cleaning process of the painting operation. The new process is as follows. 1. Wash with soap and water. 2. Clean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). Check with your paint supplier for product recommendations. 3. Scuff sand per your paint suppliers recommendations. Note: The use of a solvent-type cleaner will soften, or begin to dissolve the primer. Base coats do not have any affect on this primer. 4. Reclean with a 50% mix of isopropyl alcohol and water (or a waterborne cleaner). All fascias, with the exception of the Corvette, Camaro, and Cadillac XLR, are made of TPO. You may find other TPO parts with this primer. If the technician has a question as to the type of plastic they are painting, inspect the back of the part for the plastic symbol (TPO). Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10082 Paint: By Symptom Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10083 Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Technical Service Bulletin # 05-08-51-008C Date: 090622 Body - Bumps or Rust Colored Spots in Paint Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10084 TECHNICAL Bulletin No.: 05-08-51-008C Date: June 22, 2009 Subject: Bumps or Rust Colored Spots in Paint Due to Rail or Iron Dust (Remove Rail Dust) Models: 1994-2010 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 05-08-51-008B (Section 08 - Body and Accessories). Condition Visible rust colored spots or bumps on a vehicle's paint surface from rail or iron dust. Cause Rail dust comes from tiny iron particles produced from the friction between train wheels and the tracks and gets deposited on the vehicle surfaces. Iron dust can get deposited on the surface if the vehicle is stored near any operation producing iron dust such as an iron ore yard. Either material can lay on top of, or become embedded in, the paint surface. Correction Because the severity of the condition varies, proper diagnosis of the damage is critical to the success of repairs. Diagnosis should be performed on horizontal surfaces (hood, roof, deck lid, pick up box, etc.) after the vehicle has been properly cleaned. There are two types of repair materials recommended to repair rail dust or iron dust: 1. GEL TYPE OXALIC ACID: - Has the characteristics of the liquid type oxalic acid but stays where you put it because of its gel consistency. 2. CLAY TYPE NON-ACID BASED: - Requires surface lubricant during use. - Has different grades available. Caution Rail dust remover (Oxalic Acid) is an acidic substance containing chemicals that will break down the iron particles embedded in the finish. When working with rail dust remover, use the necessary safety equipment, including gloves and goggles. Follow the chemical manufacturer's directions closely because it may require special handling and disposal. If, upon inspection, some particles are still present, the various chemical manufacturer's processes can be repeated. After the removal process, small pits may remain in the clearcoat and can be corrected, in most cases, with a finesse/polish operation. Procedure 1. Move the vehicle to a cool shaded area and make sure that the vehicle surfaces are cool during the removal process. DO NOT PERFORM THE REMOVAL PROCESS IN DIRECT SUNLIGHT OR ON A VEHICLE WITH HOT OR WARM BODY PANELS. 2. Wash the vehicle with soap and water. Dry it immediately and clean the affected areas with a wax and grease remover. 3. Perform the removal process according to the chemical manufacturer's directions. Once the damage has been repaired, the final step involves a polishing process. Rail Dust Remover Manufacturers Use the chemical manufacturers listed below, or equivalent: Auto Magic(R) or Clay Magic(R) products available from: Auto Wax Company, Inc. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 10085 1275 Round Table Dr. Dallas, TX 75247 (800) 826-0828 (Toll-Free) or (214) 631-4000 (Local) Fax (214) 634-1342 www.automagic.com [email protected] E038 Fallout Gel or E038E Liquid Fallout Remover II available from: Valvoline Car Brite Company 1910 South State Avenue Indianapolis, In 46203 (800) 347-2439 (Toll Free) or (317) 788-9925 (Local) Fax (317) 788-9930 www.carbrite.com [email protected] *We believe these sources and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from these firms or for any such items which may be available from other sources. If rail dust remover is not available in your area, call one of the numbers listed above for a distributor near your location. Warranty Information (excluding Saab U.S. Models) Important Refer to the Policy & Procedures Manual, section 1.2.1.7 for detailed information regarding warranty coverage for this condition. Important In certain cases where the vehicle finish is severely damaged and the actual repair time exceeds the published time, the additional time should be submitted in the "Other Labor Hours" field. Warranty Information (Saab U.S. Models) Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Technician Safety Information Paint: Technician Safety Information Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Service Precautions > Technician Safety Information > Page 10088 Paint: Vehicle Damage Warnings Basecoat/Clearcoat Paint Systems CAUTION: - Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. All paint finish repairs of rigid exterior surfaces must meet GM standards. The GM Approved Refinish Materials book GM P/N GM4901M-D identifies the paint systems you may use. Always refer to the latest revision of the 4901M-D book. All approved products, including volatile organic compound (VOC) compliant regulations are listed in the system approach recommended by the individual manufacturer. Refer to the manufacturer's instructions for the detailed procedures for materials used in the paint system in the painting repairs of rigid exterior surfaces. All components of an approved paint system have been engineered in order to ensure proper adhesion between layers.If necessary, spot repairs or color blending in an open panel can be done. However, do not blend clear coat in an open panel. Always apply clearcoat to the next break point (body side molding, feature line, or the next panel) Do not mix paint systems or substitute a product of one manufacturer for another manufacturer's product. If incompatible products are used together the following problems may occur: - Lifting of primer coats caused by overly aggressive solvents in subsequent layers - Loss of adhesion between layers due to incompatibility of resin systems - Solvent popping or pin holing due to inappropriate solvent selection - Poor through-curing due to incompatible hardener resins or insufficient reactivity - Gloss reduction due to incompatible resins and/or solvents - Poor color accuracy due to pigment interactions with incompatible resins and/or solvents - Film defects (craters, blisters, orange peel loss of gloss) due to the use of inferior quality raw materials in incompatible products. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) Paint: Application and ID Color Compatibility Guide (Paint Codes) COLOR COMPATIBILITY GUIDE (Paint Codes) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10091 WA111B/95 - WA303D/25 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10092 WA303D/25 - WA379E/86 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10093 WA379E/86 - WA382E/11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10094 WA382E/11 - WA408G/44 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10095 WA408G/44 - WA519F/12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10096 WA519F/12 - WA5322/33 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10097 WA5322/33 - WA534F/54 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10098 WA534F/54 - WA5456/43 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10099 WA5456/43 - WA7156/46 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10100 WA722J/25 - WA722J/25 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10101 WA722J/25 - WA800J/98 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10102 WA800J/98 - WA805K/62 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10103 WA805K/62 - WA811K/87 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10104 WA811K/87 - WA812K/88 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10105 WA812K/88 - WA812K/88 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10106 WA812K/88 - WA815K/91 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10107 WA815K/91 - WA817K/63 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10108 WA817K/63 - WA817K/63 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10109 WA817K/63 - WA822K/97 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10110 WA822K/97 - WA8554/40 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10111 WA8554/40 - WA8554/40 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10112 WA8555/41 - WA8555/41 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10113 WA8555/41 - WA8555/41 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10114 WA8555/41 - WA8555/41 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10115 WA8555/41 - WA8555/41 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10116 WA8555/41 - WA8624/50 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10117 WA8624/50 - WA8624/50 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10118 WA8624/50 - WA8624/50 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10119 WA8743/28 - WA885K/70 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10120 WA885K/70 - WA913L/56 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10121 WA913L/56 - WA9260/74 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10122 WA9260/74 - WA9260/74 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10123 WA9260/74 - WA926L/59 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10124 WA926L/59 - WA929L/15 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10125 WA929L/15 - WA931L/68 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10126 WA931L/68 - WA9417/88 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10127 WA9417/88 - WA9539/47 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10128 WA9539/47 - WA9566/13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10129 WA9566/13 - WA964L/29 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10130 WA964L/29 - WA9792/39 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10131 WA9800/77 - WA994L/67 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10132 WA994L/67 - WA994L/67 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10133 WA994L/67 - WA994L/67 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10134 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10135 Paint: Application and ID Paint Identification Precautions PAINT IDENTIFICATION Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM PIN 4901 MD This book identities the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: 1. A cathodic immersion primer 2. A primer/surfacer 3. A basecoat 4. A clear top coat (clearcoat) Refer to the Service Parts ID Label to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10136 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10137 Paint: Application and ID Color Compatibility Guide (Paint Codes) COLOR COMPATIBILITY GUIDE (Paint Codes) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10138 WA111B/95 - WA303D/25 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10139 WA303D/25 - WA379E/86 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10140 WA379E/86 - WA382E/11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10141 WA382E/11 - WA408G/44 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10142 WA408G/44 - WA519F/12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10143 WA519F/12 - WA5322/33 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10144 WA5322/33 - WA534F/54 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10145 WA534F/54 - WA5456/43 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10146 WA5456/43 - WA7156/46 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10147 WA722J/25 - WA722J/25 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10148 WA722J/25 - WA800J/98 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10149 WA800J/98 - WA805K/62 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10150 WA805K/62 - WA811K/87 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10151 WA811K/87 - WA812K/88 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10152 WA812K/88 - WA812K/88 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10153 WA812K/88 - WA815K/91 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10154 WA815K/91 - WA817K/63 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10155 WA817K/63 - WA817K/63 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10156 WA817K/63 - WA822K/97 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10157 WA822K/97 - WA8554/40 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10158 WA8554/40 - WA8554/40 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10159 WA8555/41 - WA8555/41 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10160 WA8555/41 - WA8555/41 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10161 WA8555/41 - WA8555/41 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10162 WA8555/41 - WA8555/41 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10163 WA8555/41 - WA8624/50 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10164 WA8624/50 - WA8624/50 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10165 WA8624/50 - WA8624/50 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10166 WA8743/28 - WA885K/70 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10167 WA885K/70 - WA913L/56 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10168 WA913L/56 - WA9260/74 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10169 WA9260/74 - WA9260/74 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10170 WA9260/74 - WA926L/59 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10171 WA926L/59 - WA929L/15 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10172 WA929L/15 - WA931L/68 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10173 WA931L/68 - WA9417/88 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10174 WA9417/88 - WA9539/47 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10175 WA9539/47 - WA9566/13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10176 WA9566/13 - WA964L/29 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10177 WA964L/29 - WA9792/39 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10178 WA9800/77 - WA994L/67 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10179 WA994L/67 - WA994L/67 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10180 WA994L/67 - WA994L/67 Paint Identification Precautions PAINT IDENTIFICATION Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important Always refer to the GM Approved Refinish Materials book GM PIN 4901 MD This book identities the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: 1. A cathodic immersion primer 2. A primer/surfacer 3. A basecoat Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10181 4. A clear top coat (clearcoat) Refer to the Service Parts ID Label to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Application and ID > Color Compatibility Guide (Paint Codes) > Page 10182 Paint Identification Paint Identification Caution: Exposure to isocyanates during paint preparation and application processes can cause severe breathing problems. Read and follow all of the instructions from the manufacturers of painting materials, equipment, and protective gear. Important: Always refer to the GM Approved Refinish Materials book GM P/N 4901M-D. This book identifies the paint systems you may use. The basecoat/clearcoat paint is factory applied in the following 4 layers in order to give the finish a high gloss look: * A cathodic immersion primer * A primer/surfacer * A basecoat * A clear top coat (clearcoat) Refer to Label - Service Parts ID in General Information in order to identify the type of top coat on the vehicle. This label contains all paint related information for the vehicle. This includes paint technology, paint codes, trim level, and any special order paint colors. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Radiator Support > Component Information > Description and Operation Radiator Support: Description and Operation Radiator Support Description Radiator Support Assembly The radiator support can be serviced as a complete assembly. The radiator is made up of 5 major components: * Four upper * One lower Upper Radiator Support The upper radiator support is an assembly consisting of four components: * Two-piece upper tie bar * Left and Right engine compartment front panels Lower Radiator Support The lower radiator support is available as a separate replaceable component if necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Procedures Seat Heater Control Module: Procedures HEATED SEAT CONTROL MODULE REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Position the seat to the full-up position. 2. Remove the bolts that secure the front seat frame to the floor. 3. Rotate the seat forward to access the heater module. 4. Disconnect the seat electrical harness connector. 5. Disconnect the heater control module from the seat frame by sliding the control module toward the front of the seat. 6. Disconnect the electric harness connector (1) from the heater module (2). 7. Remove the heater module from the front seat. INSTALLATION PROCEDURE 1. Position the heater module to the front seat. 2. Connect the electrical harness connector (1) to the heater module (2). 3. Position the module on the frame and slide the module rearward until the module locks into place. 4. Lower the seat. 5. Connect the seat electrical harness connector. NOTE: Refer to Fastener Notice in Service Precautions. 6. Install the bolts that secure the front bucket seat adjuster to the floor pan. Tighten Tighten the bolts to 42 N.m (31 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Procedures > Page 10191 7. Reposition the front seat to the original position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module > Component Information > Service and Repair > Procedures > Page 10192 Seat Heater Control Module: Removal and Replacement Heated Seat Control Module Replacement - Front Removal Procedure 1. Position the seat to the full-up position. 2. Remove the bolts that secure the front seat frame to the floor. 3. Rotate the seat forward to access the heater module. 4. Disconnect the seat electrical harness connector. 5. Disconnect the heater control module from the seat frame by sliding the control module toward the front of the seat. 6. Disconnect the electrical harness connector (1) from the heater module (2). 7. Remove the heater module from the front seat. Installation Procedure 1. Position the heater module to the front seat. 2. Connect the electrical harness connector (1) to the heater module (2). 3. Position the module on the frame and slide the module rearward until the module locks into place. 4. Lower the seat. 5. Connect the seat electrical harness connector. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bolts that secure the front bucket seat adjuster to the floor pan. Tighten the bolts to 42 N.m (31 lb ft). 7. Reposition the front seat to the original position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Diagrams Seat Heater Relay: Diagrams Heated Seat Relay-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Relay > Component Information > Diagrams > Page 10196 Heated Seat Relay-Front Passenger Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof / Moonroof Module: Diagrams Sunroof Module, C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Page 10200 Sunroof Module, C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Page 10201 Sunroof / Moonroof Module: Service and Repair SUNROOF CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the headliner. 2. Remove the nylon tie straps located from both ends of the sunroof control module (2). 3. Release the control module retainers from the metal bracket by sliding the control module toward the left side of the vehicle. 4. Remove the control module from the sunroof module. 5. Disconnect the electrical connectors from the control module. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Sunroof / Moonroof Module > Component Information > Diagrams > Page 10202 6. Remove the control module from the vehicle. INSTALLATION PROCEDURE 1. Position the control module to the sunroof module. 2. Connect the electrical connectors to the ends of the control module. 3. Install the control module to the sunroof module by sliding it to the right to engage the retainers. 4. Install the nylon tie straps at both ends of the control module (2). 5. Check the operation of the sunroof module. 6. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunshade Anchor Replacement Sun Shade: Service and Repair Sunshade Anchor Replacement SUNSHADE ANCHOR REPLACEMENT REMOVAL PROCEDURE 1. Unhook the sunshade from the sunshade anchor. 2. Remove the screw from the sunshade anchor. 3. Remove the sunshade anchor from the roof. INSTALLATION PROCEDURE 1. Position the sunshade anchor to the mounting position in the roof. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screw to the sunroof anchor. Tighten Tighten the sunroof anchor screw to 3 N.m (27 lb in). 3. Reposition the sunshade to the original position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunshade Anchor Replacement > Page 10209 Sun Shade: Service and Repair Sunroof Sunshade Panel Replacement SUNROOF SUNSHADE PANEL REPLACEMENT REMOVAL PROCEDURE 1. Remove the sunroof window panel. 2. Use a flat-bladed tool to push the sunshade slide blocks into the sunshade to release them from the sunroof guide assembly on one side of the sunshade. Hold the slide blocks in the released position and lift that side of the sunshade up. 3. Remove the sunshade panel through the roof opening. INSTALLATION PROCEDURE 1. Install the sunshade panel through the roof opening. 2. Insert the slide blocks on the right side of the sunshade into the sunroof guide assembly. 3. Push the sunshade slide locks on the left side of the sunshade into the sunshade to allow the sunshade to drop into position. Once the sunshade is in position, engage slide blocks into the left guide assembly. 4. Slide the sunshade forward and backward to check for smooth operation. 5. Install the sunroof window panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sun Shade > Component Information > Service and Repair > Sunshade Anchor Replacement > Page 10210 Sun Shade: Service and Repair Sunroof Sunshade Stop Replacement SUNROOF SUNSHADE STOP REPLACEMENT REMOVAL PROCEDURE 1. Remove the headliner. 2. Remove the sunshade stop screw from the sunshade track. 3. To remove the sunshade stop, press the sunshade stop locking tab in and slide sunshade stop out of the sunshade track. INSTALLATION PROCEDURE 1. Position the sunshade stop to the sunshade track. 2. Press the sunshade stop into the sunshade track until fully seated. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the sunshade stop screw to the sunshade track. Tighten Tighten the sunshade stop screw to 2 N.m (18 lb in). 4. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations Sunroof Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 10214 Sunroof Motor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Locations > Page 10215 Sunroof / Moonroof Motor: Description and Operation SUNROOF MOTOR The sunroof has a bi-directional motor. When the motor is not operating both circuits are grounded. When the motor drives the sunroof glass in the direction from the closed to vent or vent to open position, the following occurs: - Voltage is supplied to the sunroof motor/actuator open control circuit. - Ground is maintained to the sunroof motor/actuator close control circuit. When the motor drives the sunroof in the direction from the open to vent or vent to closed position, the following occurs: - Voltage is supplied to the sunroof motor/actuator close control circuit. - Ground is maintained to the sunroof motor open control circuit. The sunroof control module is equipped with a timer circuit which stops the operation of the sunroof motor after 8 seconds. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > MD4 Sunroof / Moonroof Motor: Service and Repair MD4 Sunroof Motor/Actuator Replacement (MD4) Removal Procedure Important: The sunroof actuator drive shaft turns in both directions and contains no limit switches. The sunroof actuator may be replaced with the window panel in any position. 1. Remove the headliner. 2. Remove the tie strap from the wiring harness. 3. Remove the screws from the sunroof motor/actuator (1). 4. Disconnect the electrical connector from the wiring harness. 5. Pull straight down to disengage the drive gear from the sunroof opening positioning switch (SOPS). 6. Remove the sunroof motor/actuator from the sunroof module. Installation Procedure 1. Position the sunroof motor/actuator to the sunroof module. 2. Connect the electrical connector to the wiring harness. 3. Push the sunroof motor/actuator straight in to engage its drive gear into the SOPS. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > MD4 > Page 10218 Notice: Refer to Fastener Notice in Service Precautions. 4. Install the sunroof actuator screws (1) to the sunroof actuator. Tighten Tighten the sunroof actuator screws to 3 Nm (27 lb in). 5. Install the tie strap to the wiring harness (2). 6. Perform the Initialization/Teach Procedure. See: Testing and Inspection/Programming and Relearning/Sunroof Motor/Actuator Initialization/Teach Process 7. Inspect the operation of the sunroof module. 8. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > MD4 > Page 10219 Sunroof / Moonroof Motor: Service and Repair PES Sunroof Motor/Actuator Replacement (PES) Tools Required J 41718 Sunroof Timing Pins Removal Procedure Important: This sunroof system is timed from the factory in order to allow the actuator to shut off automatically when the sunroof window reaches a certain position. Use extreme care when removing the sunroof actuator from the sunroof module. Improper removal may cause the timing to be thrown off. Anytime the sunroof actuator requires removal from the sunroof module, ensure that the sunroof window is in the fully closed position and the sunroof timing pins are installed. 1. Position the sunroof window panel to the fully closed position. 2. Remove the headliner. 3. Remove the right and left front screw from the sunroof window panel. Important: Before removing the sunroof actuator, ensure that J 41718 are tight and holding the cable. 4. Install J 41718 into the front sunroof window panel screw hole in order to retain the cable adjustment. 5. Disconnect the electrical connector from the sunroof module actuator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > MD4 > Page 10220 6. Remove the bolts from the sunroof actuator. 7. Remove the sunroof actuator from the sunroof module. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Service and Repair > MD4 > Page 10221 1. Install the sunroof actuator to the sunroof module. Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems. 2. Install the sunroof actuator bolts. Tighten Tighten the sunroof actuator bolts to 4 Nm (35 lb in). 3. Connect the electrical connector to the sunroof actuator. 4. Remove the sunroof timing pins. 5. Install the front screws to the sunroof window panel. 6. Check the sunroof for proper operation. 7. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Locations Sunroof Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Sunroof Switch (Without RPO Code U68) Sunroof Switch (Without RPO Code U68) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Sunroof Switch (Without RPO Code U68) > Page 10227 Sunroof Opening Position Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 10228 Sunroof / Moonroof Switch: Description and Operation SUNROOF OPENING POSITION SWITCH The Sunroof Opening Position Switch tracks the position of the glass through 2 limit switches: - Soft Stop limit - Vent limit The sunroof control module monitors the limit switches and based on the inputs determines the position of the sunroof glass. As a limit switch closes, the 5 volt reference will be shorted to the sunroof limit switch low reference circuit, pulling the 5 volt reference to 0 volts. The sunroof control module understands the position of the sunroof glass based on the different input combinations through the soft stop and vent limit switch inputs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch Replacement (w/o Overhead Console) Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (w/o Overhead Console) Sunroof Switch Replacement (w/o Overhead Console) Removal Procedure 1. Grasp the power sunroof switch on the left and right sides. Important: The switch must be rotated, pulled down on the left side, to be removed. 2. Use 2, small, flat-bladed tools in order to disengage the clips which are located at the front and rear of the power sunroof switch. Hold the flat-bladed tools parallel to the roof and push straight in. 3. Rotate the power sunroof switch toward the left side to disengage it from the mounting bracket and pull down. 4. Disconnect the electrical connector from the power sunroof switch. 5. Remove the power sunroof switch from the vehicle. Installation Procedure 1. Connect the electrical connector to the power sunroof switch. 2. Rotate the power sunroof switch back into the vehicle. 3. Firmly push the power sunroof switch into the headliner until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch Replacement (w/o Overhead Console) > Page 10231 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (With Overhead Console) Sunroof Switch Replacement (With Overhead Console) Removal Procedure Important: The driver information center control module, and the power sunroof switch is serviced as a complete part. 1. Remove the overhead console. 2. Remove the driver information center control module, containing the power sunroof switch from the overhead console. Installation Procedure 1. Install the driver information center control module, containing the power sunroof switch to the overhead console. 2. Install the overhead console. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch Replacement (w/o Overhead Console) > Page 10232 Sunroof / Moonroof Switch: Service and Repair Sunroof Opening Position Switch Replacement Sunroof Opening Position Switch Replacement Tools Required J 41718 Sunroof Timing Pins Removal Procedure Important: ^ The Sunroof Opening Position Switch (SOPS) (3) is aligned to the drive cables. The switch comes from the factory set to the window panel CLOSED position. A position lock pin (1) has been installed on the top of the switch. The pin (1) must remain until after the installation of the actuator and of the switch. The lock pin locks the drive gears in place and must be removed before operation of the sunroof module. ^ If you reuse a Sunroof Opening Position Switch, place the sunroof window panel in the CLOSED position. Install the sunroof timing pins J 41718. Install a position lock pin, or install 2 wires, such as the ends of a paper clip, then remove the SOPS from the sunroof module. The SOPS timing will be lost if you do not follow this procedure. 1. Position the sunroof window panel to the closed position. 2. Remove the sunroof module from the vehicle. Important: Before removing the SOPS from the sunroof module, the J 41718 sunroof timing pins must be installed to lock the cable/cam mechanism into position. 3. The cable/cam mechanisms, on both sides of the sunroof window, contain a set of timing holes. These holes are aligned to the sunroof window panel in the CLOSED position. Remove the left and right side front sunroof window panel screws. Align the timing holes. Use a flat-bladed tool to push the cable/cam mechanism forward or rearward. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch Replacement (w/o Overhead Console) > Page 10233 Install the J 41718 sunroof timing pins into the left and right sunroof window panel screw holes. 4. Remove the sunroof actuator. 5. Disconnect the electrical connector from the SOPS (3). 6. Remove the SOPS screw (2) from the switch. 7. Hold down on both drive cables, and lift straight up to remove the SOPS from the sunroof module. Installation Procedure Important: The new SOPS comes with a position lock pin that is installed on top of the SOPS. This locks the timing gears in place. Do not remove this pin until after you have installed the SOPS and the actuator. 1. Keeping the position lock pin in the new SOPS, position the SOPS switch over the drive cables and press down. If the SOPS does not slide into position, the ridges on the drive cable housings will not go into the grooves on the back of the SOPS. Lift each cable into the SOPS, and press down on the SOPS assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch Replacement (w/o Overhead Console) > Page 10234 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the Sunroof opening Position Switch screw (2) to the switch. Tighten Tighten the SOPS screw to 2 N.m (18 lb in). 3. Connect the electrical connector to the SOPS. 4. Install the sunroof actuator. 5. Remove the position lock pin (1) or the 2 wires from the switch. 6. Remove the 2 pins from the cable/cam mechanisms. 7. Install the left and right front sunroof window panel screws. Tighten Tighten the front sunroof window panel screws to 4 N.m (35 lb in). 8. Install the sunroof module, but do not install the headliner until after you have tested the sunroof operation. 9. Inspect the operation of the sunroof. 10. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Drain: > 04-08-57-007B > Dec > 05 > Body/Interior - Headliner is Wet Around Sunroof Sunroof / Moonroof Drain: Customer Interest Body/Interior - Headliner is Wet Around Sunroof Bulletin No.: 04-08-57-007B Date: December 06, 2005 TECHNICAL Subject: Headliner Wet Around Sun Roof (Modify Drain Hose) Models: 2004-2005 Chevrolet Monte Carlo, Impala 2004-2005 Pontiac Grand Prix Supercede: This bulletin is being revised to add leak repair verification steps. Please discard Corporate Bulletin Number 04-08-57-007A (Section 08 - Body and Accessories). Condition Some customers may comment that the headliner is wet or that water is dripping out of the overhead reading lamp. Cause Both front corners of the sunroof have a drain hose running down the A pillar and end up down at the floor behind the lower kick pad on the left or right side. The end of the sunroof drain hoses may be laying flat against the foam at the base of the "A" pillar. This may cause a partially plugged drain hose. During a heavy rain, water that should be draining away may back up and overflow into the headliner at the front of the vehicle. Correction 1. Remove the lower right hand and left hand lower kick pad. 2. After locating the hose, cut the end of the hose into a point. 3. Verify that the lower "A" pillar drains are open by pouring a cup of water in the bottom of the "A" pillar. 4. Check the drain hoses from the sunroof down to the bottom of the "A" pillar by using shop air. 5. Reinstall the kick pad. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Drain: > 04-08-57-007B > Dec > 05 > Body/Interior - Headliner is Wet Around Sunroof > Page 10243 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Drain: > 04-08-57-007B > Dec > 05 > Body/Interior - Headliner is Wet Around Sunroof Sunroof / Moonroof Drain: All Technical Service Bulletins Body/Interior - Headliner is Wet Around Sunroof Bulletin No.: 04-08-57-007B Date: December 06, 2005 TECHNICAL Subject: Headliner Wet Around Sun Roof (Modify Drain Hose) Models: 2004-2005 Chevrolet Monte Carlo, Impala 2004-2005 Pontiac Grand Prix Supercede: This bulletin is being revised to add leak repair verification steps. Please discard Corporate Bulletin Number 04-08-57-007A (Section 08 - Body and Accessories). Condition Some customers may comment that the headliner is wet or that water is dripping out of the overhead reading lamp. Cause Both front corners of the sunroof have a drain hose running down the A pillar and end up down at the floor behind the lower kick pad on the left or right side. The end of the sunroof drain hoses may be laying flat against the foam at the base of the "A" pillar. This may cause a partially plugged drain hose. During a heavy rain, water that should be draining away may back up and overflow into the headliner at the front of the vehicle. Correction 1. Remove the lower right hand and left hand lower kick pad. 2. After locating the hose, cut the end of the hose into a point. 3. Verify that the lower "A" pillar drains are open by pouring a cup of water in the bottom of the "A" pillar. 4. Check the drain hoses from the sunroof down to the bottom of the "A" pillar by using shop air. 5. Reinstall the kick pad. Warranty Information For vehicles repaired under warranty, use the table. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Drain: > 04-08-57-007B > Dec > 05 > Body/Interior - Headliner is Wet Around Sunroof > Page 10249 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Hose Replacement - Front Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Hose Replacement - Front SUNROOF DRAIN HOSE REPLACEMENT - FRONT (IMPALA) REMOVAL PROCEDURE 1. Remove the front carpet retainer. 2. Remove the headliner. 3. Reposition the carpet in order to gain access to the access hole in the front pillar. 4. Disconnect the front sunroof drain hose from the sunroof module front spigot. 5. Tie a string to the hose at the module end of the front sunroof drain hose. 6. Remove the grommet at the end of the front sunroof drain hose from the hole in the front pillar. 7. Remove the front sunroof drain hose from the front pillar, by pulling the hose from the access hole in the front pillar, allowing the string to remain in the pillar. INSTALLATION PROCEDURE 1. Tie the string to the hose at the front sunroof drain hose by the sunroof module. 2. Install the front sunroof drain hose, by pulling the string from the front pillar access hole and routing the front sunroof drain hose through the front pillar. 3. Remove the string from the front sunroof drain hose. 4. Install the end of the front sunroof drain hose to the grommet in the hole in the front pillar. 5. Connect the front sunroof drain hose to the sunroof module front spigot. 6. Inspect the front sunroof drain hose for proper installation. 7. Position the carpet back in place. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Hose Replacement - Front > Page 10252 8. Install the front carpet retainer. 9. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Hose Replacement - Front > Page 10253 Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Hose Replacement - Rear SUNROOF DRAIN HOSE REPLACEMENT - REAR (IMPALA) REMOVAL PROCEDURE 1. Remove the headliner. 2. Remove the rear quarter lower trim panel. 3. Disconnect the rear sunroof drain hose from the sunroof module rear spigot. 4. Remove the tape from the rear sunroof drain hose tube. 5. Disconnect the rear sunroof drain hose from the rear sunroof drain hose tube. 6. Remove the rear sunroof drain hose tube from the upper retainer clip. 7. Remove the rear sunroof drain hose from the rear pillar. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Hose Replacement - Front > Page 10254 1. Position the rear sunroof drain hose to the rear pillar. 2. Route the rear sunroof drain hose (1) to the lower access hole in the quarter inner panel. 3. Install the rear sunroof drain hose tube to the upper retainer clip. 4. Route the rear sunroof drain hose to the outboard edge of the rear pillar and secure with tape. 5. Connect the rear sunroof drain hose to the sunroof module rear drain tube. 6. Connect the rear sunroof drain hose (1) to the rear sunroof drain hose tube. 7. Install the rear quarter lower trim panel. 8. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Drain > Component Information > Service and Repair > Sunroof Drain Hose Replacement - Front > Page 10255 Sunroof / Moonroof Drain: Service and Repair Sunroof Drain Inspection and Cleaning Sunroof Drain Inspection and Cleaning Drain Hose Routing A drain trough encircles the sunroof window panel and water is drained off by the drain hoses located at each corner of the housing. A drain channel spans across the sunroof module at the rear of the window panel and directs water into the trough. 1. Check to ensure the front drain hoses are routed down the windshield pillars and out the center of the pillar between the door hinges. Make sure the hoses are not kinked. Replace any torn or cracked hose. Refer to Sunroof Drain Hose Replacement - Front (Impala) Sunroof Drain Hose Replacement - Front (Monte Carlo). 2. Check to ensure the rear drain hoses are routed through the rear pillars and out of the rocker panel. Make sure the rear hoses are properly routed in the metal roof slot and taped in place. Replace any torn or cracked hose. Refer to Sunroof Drain Hose Replacement - Rear (Impala) Sunroof Drain Hose Replacement - Rear (Monte Carlo). Plugged Drain Hose If a waterleak has occurred check for a plugged drain hose at each corner of drainage system. 1. Open the sunroof window. 2. To test for blockage, pour a small container of water into the module housing drain trough. Check each corner to confirm the drain hose is draining water. Caution: Wear safety glasses in order to avoid eye damage. 3. Use compressed air, 241 kpi (35 psi) or less to blow out any drain hose that is plugged. 4. Test the system again. 5. If the hose remains plugged, check to see it is properly routed and does not have a kink. Refer to Drain Hose Routing. 6. Remove any hoses that remain plugged. 7. Remove the blockage using the following steps. 1. Push mechanics wire through the hose to remove the obstruction. 2. Use compressed air in order to blow out any remaining material. 3. Reinstall the hose. Disconnected Drain Hose Inspect the drainage system for disconnected drain hoses. Complete the following steps in order to obtain partial access to drain hoses and check for a disconnected hose. 1. Open the sunroof window panel. 2. Lower the headliner as needed. Refer to Headliner Replacement (Impala) Headliner Replacement (Monte Carlo) in Interior Trim. 3. Connect any disconnected hoses. 4. Ensure that the rear drain hoses are properly routed in the metal roof slot and taped in place. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams Sunroof / Moonroof Module: Diagrams Sunroof Module, C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Page 10259 Sunroof Module, C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Page 10260 Sunroof / Moonroof Module: Service and Repair SUNROOF CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the headliner. 2. Remove the nylon tie straps located from both ends of the sunroof control module (2). 3. Release the control module retainers from the metal bracket by sliding the control module toward the left side of the vehicle. 4. Remove the control module from the sunroof module. 5. Disconnect the electrical connectors from the control module. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Module > Component Information > Diagrams > Page 10261 6. Remove the control module from the vehicle. INSTALLATION PROCEDURE 1. Position the control module to the sunroof module. 2. Connect the electrical connectors to the ends of the control module. 3. Install the control module to the sunroof module by sliding it to the right to engage the retainers. 4. Install the nylon tie straps at both ends of the control module (2). 5. Check the operation of the sunroof module. 6. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments Sunroof / Moonroof Panel: Adjustments Sunroof Window Height and Opening Fit Adjustment 1. Slide the sunroof sunshade to the open position. 2. Move the sunroof glass panel to the fully closed position. 3. Loosen the sunroof glass panel screws. 4. Individually adjust the 4 corners (1) of the sunroof glass panel. 5. Adjust the front of the sunroof glass panel to 0.5 mm (0.020 in) below the top surface of the roof panel (3). 6. Adjust the rear of the sunroof glass panel to 0.5 mm (0.020 in) above the top surface of the roof panel (2). Notice: Refer to Fastener Notice in Service Precautions. 7. Tighten the sunroof glass panel screws. Tighten Tighten the screws to 4 N.m (35 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Panel > Component Information > Adjustments > Page 10265 Sunroof / Moonroof Panel: Service and Repair SUNROOF WINDOW REPLACEMENT REMOVAL PROCEDURE 1. Position the sunshade panel fully rearward. 2. Position the sunroof window panel to the vent position. 3. Remove the sunroof window panel screws from the sunroof window panel. 4. Remove the sunroof window panel from the sunroof module. INSTALLATION PROCEDURE 1. Position the sunroof window panel to the sunroof module. Ensure that the information logo stencil is towards the rear of the sunroof opening. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the sunroof window panel screws to the sunroof window panel. Tighten Tighten the sunroof window panel screws to 4 N.m (35 lb in). 3. Adjust the sunroof window panel as necessary. Refer to Sunroof Window Height and Opening Fit Adjustment. 4. Inspect the sunroof window panel for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Wiring Harness > Component Information > Service and Repair Sunroof / Moonroof Wiring Harness: Service and Repair SUNROOF WIRING HARNESS REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Note the following locations: The position of the wire harness routing - The location of the tie-straps that secure the harness to the drive cable tubes and the sunroof express module 1. Position the sunshade in the full forward position. 2. Remove the headliner. 3. Remove the rear shelf. 4. Cut the nylon tie straps on the express module and the drive cable tube. 5. Disconnect the electrical connector from the following components: - The sunroof express module - The sunroof actuator - The Position Encoding Switch 6. Remove the tape holding the wire harness to the module. 7. Remove the wire harness from the sunroof. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Wiring Harness > Component Information > Service and Repair > Page 10269 1. Position the wire harness to the sunroof. 2. Connect the electrical connectors to the following components: - The sunroof express module - The sunroof actuator - The Position Encoding Switch 3. Install new nylon tie straps to the express module and the drive cable tubes. 4. Install new tape to hold the wire harness to the module. 5. Check for proper operation of the sunroof. Refer to Sunroof Description and Operation. 6. Install the rear shelf. 7. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures Head Rest: Procedures Head Restraint Replacement - Front Seat HEAD RESTRAINT REPLACEMENT - FRONT SEAT REMOVAL PROCEDURE 1. Raise the front seat head restraint to the full up position. 2. Press in the release tab (1) at the side of the head restraint retainer. 3. Remove the front seat head restraint from the front seat. INSTALLATION PROCEDURE 1. Align the head restraint to the head restraint retainers in the front seat back. 2. Install the head restraint to the front seat, pressing down until fully seated. 3. Raise the head restraint to the full up position to ensure the head restraint stops at the detent. 4. Position the head restraint to its original position. Head Restraint Retainer Replacement - Front Seat HEAD RESTRAINT RETAINER REPLACEMENT - FRONT SEAT REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 10275 1. Remove the head restraint from the front seat. 2. Position the front seat back to the full upright position. 3. Unhook the J-hook retainer at the bottom of the seat back cover. 4. Pull up on the front seat cover to enlarge the opening for access to the front seat frame. IMPORTANT: The use of a small, flat-bladed tool as a lever under the top of the retainer will help in the removal of the head restraint retainer. 5. Reach carefully inside the front seat back between the seat back cover and the seat back pad and squeeze the bottom of the head restraint retainer together, while pulling the head restraint retainer upwards from the seat back frame. 6. Remove the head restraint retainer from the front seat back frame. INSTALLATION PROCEDURE 1. Install the guide to the seat back frame, pressing in until fully seated into the front seat frame. 2. Reposition the front seat cover to the front seat back. 3. Close the J-hook retainer at the bottom edge of the front seat back cover. 4. Install the head restraint to the front seat. 5. Return the front seat back to the original position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 10276 Head Rest: Removal and Replacement Head Restraint Replacement - Front Seat Head Restraint Replacement - Front Seat Removal Procedure 1. Raise the front seat head restraint to the full up position. 2. Press in the release tab (1) at the side of the head restraint retainer. 3. Remove the front seat head restraint from the front seat. Installation Procedure 1. Align the head restraint to the head restraint retainers in the front seat back. 2. Install the head restraint to the front seat, pressing down until fully seated. 3. Raise the head restraint to the full up position to ensure the head restraint stops at the detent. 4. Position the head restraint to its original position. Head Restraint Retainer Replacement - Front Seat Head Restraint Retainer Replacement - Front Seat Removal Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Rest > Component Information > Service and Repair > Procedures > Page 10277 1. Remove the head restraint from the front seat. 2. Position the front seat back to the full upright position. 3. Unhook the J-hook retainer at the bottom of the seat back cover. 4. Pull up on the front seat cover to enlarge the opening for access to the front seat frame. Important: The use of a small, flat-bladed tool as a lever under the top of the retainer will help in the removal of the head restraint retainer. 5. Reach carefully inside the front seat back between the seat back cover and the seat back pad and squeeze the bottom of the head restraint retainer together, while pulling the head restraint retainer upwards from the seat back frame. 6. Remove the head restraint retainer from the front seat back frame. Installation Procedure 1. Install the guide to the seat back frame, pressing in until fully seated into the front seat frame. 2. Reposition the front seat cover to the front seat back. 3. Close the J-hook retainer at the bottom edge of the front seat back cover. 4. Install the head restraint to the front seat. 5. Return the front seat back to the original position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Head Restraint System > System Information > Technical Service Bulletins > Restraints - Driver/Passenger Seat Head Rest Information Head Restraint System: Technical Service Bulletins Restraints - Driver/Passenger Seat Head Rest Information INFORMATION Bulletin No.: 10-08-50-003A Date: March 24, 2011 Subject: Information on Driver or Passenger Seat Head Restraint Concerns with Comfort, Custom Upholstery or Other Comfort Enhancing Devices Models: 2012 and Prior GM Passenger Cars and Trucks Equipped with Adjustable Head Restraints Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 10-08-50-003 (Section 08 - Body and Accessories). Important ON A GM VEHICLE EQUIPPED WITH ADJUSTABLE HEAD RESTRAINTS, USE THE HEAD RESTRAINT COVERS, FOAM AND OTHER SEAT-RELATED EQUIPMENT AS RELEASED BY GM FOR THAT VEHICLE. DO NOT ALTER OR REPOSITION THE HEAD RESTRAINT SYSTEM. ANY ALTERATIONS TO HEAD RESTRAINTS DEFEATS THE INTENDED DESIGN OF THE SYSTEM. GM WILL NOT BE LIABLE FOR ANY PROBLEMS CAUSED BY USE OF SUCH IMPROPER DESIGN ALTERATIONS, INCLUDING ANY WARRANTY REPAIRS INCURRED. You may have a customer with a concern that the head restraint is uncomfortable or sits too far forward. The front driver and passenger seats are equipped with head restraints that have been designed to help minimize injuries while still providing comfort to the occupants. Each GM vehicle has its own specifically designed head restraint. The head restraints should only be used in the vehicle for which they were designed. The head restraint will not operate to its design intent if the original foam is replaced (1) by non-GM foam or head restraint, (2) by GM foam or head restraint designed for a different vehicle, (3) by GM foam or head restraint that has been altered by a trim shop or (4) if any object, such as an aftermarket comfort enhancing pad or device, is installed. Never modify the design of the head restraint or remove the head restraint from the vehicle as this may interfere with the operation of the seating and restraint systems and may prevent proper positioning of the passenger within the vehicle. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Description and Operation > Personalization Memory Positioning Systems: Description and Operation Personalization PERSONALIZATION DESCRIPTION AND OPERATION Personalization features may be set for the vehicle or the driver. Vehicle features do not change with each driver. Specific drivers are recognized by the vehicle through the keyless entry transmitters, the memory buttons, or the driver information center (DISC), and the personalization settings for that driver are recalled. For more information on vehicle personalization features for this vehicle, refer to Vehicle Personalization. This vehicle does not have specific driver personalization available. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 10286 Memory Positioning Systems: Description and Operation Driver Personalization DRIVER PERSONALIZATION PERSONAL CHOICE RADIO CONTROLS With this feature the vehicle will recall the latest radio settings as adjusted the last time the vehicle was operated. Perform the following steps in order to Personalize the Personal Choice Radio Controls feature: 1. Press the Unlock button on key fob 1. 2. Turn the ignition to Run. 3. Select and Set all of the following settings: - AM/FM presets - Last tuned station - Volume - Tone - Audio source; Radio, Cassette or CD 4. Turn ignition Off. Repeat this procedure using key fob 2 to program the desired settings for driver 2. ADDITIONAL INFORMATION Refer to Radio/Audio System Description and Operation in Radio, Stereo and Compact Disc for more information about the Personal Choice Radio Controls feature. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 10287 Memory Positioning Systems: Description and Operation Vehicle Personalization VEHICLE PERSONALIZATION PROGRAMMING FEATURES ENTER PROGRAMMING MODE Perform the following steps in order to enter the programming mode: 1. Press the DISP button on radio for at least 10 seconds. 2. Press the SEEK button to scroll through the menu. DELAYED HEADLAMP ILLUMINATION Continue with the following steps in order to personalize the delayed headlamp illumination feature: 1. Scroll through the menu, using the SEEK button, until LT. DELAY is displayed. 2. Press the DISP button to enter the menu. 3. Press the PREV or NEXT button to scroll through the following options: - DISABLED - 30 SEC - 60 SEC - RETURN 4. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. AUTOMATIC DOOR LOCKS Continue with the following steps in order to personalize the automatic door locks feature: 1. Scroll through the menu, using the SEEK button, until AUTOLOCK is displayed. 2. Press the DISP button to enter the menu. 3. Press the PREV or NEXT button to scroll through the following options: - OFF - LCK ONLY - DRVR UNL - ALL UNL 4. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. REMOTE ACTIVATION VERIFICATION Continue with the following steps in order to personalize the remote activation verification feature: 1. Scroll through the menu, using the SEEK button, until FOBLIGHT is displayed. 2. Press the DISP button to enter the menu. 3. Press the PREV or NEXT button to scroll through the following options: - OFF - ON 4. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. 5. Exit to the MAIN MENU. 6. Scroll through the menu, using the SEEK button, until FOBHORN is displayed. 7. Press the DISP button to enter the menu. 8. Press the PREV or NEXT button to scroll through the following options: - OFF - PARTIAL - FULL 9. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. CONTENT THEFT DETERRENT Continue with the following steps in order to personalize the content theft deterrent options: 1. Scroll through the menu, using the SEEK button, until ALARM is displayed. 2. Press the DISP button to enter the menu. 3. Press the PREV or NEXT button to scroll through the following options: - OFF - ON 4. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. 5. Exit to the MAIN MENU. 6. Scroll through the menu, using the SEEK button, until TRNKJAMB is displayed. 7. Press the DISP button to enter the menu. 8. Press the PREV or NEXT button to scroll through the following options: - OFF - ON 9. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 10288 HORN CHIRP TIMER Continue with the following steps in order to personalize the duration of the horn chirp when the remote keyless transmitter is used: 1. Scroll through the menu, using the SEEK button, until CHIRP is displayed. 2. Press the DISP button to enter the menu. 3. Press the PREV or NEXT button to scroll through the following options: - SHORT - Short Chirp (16 msec) - LONG - Long Chirp (32 msec) 4. Press the DISP button in order to choose the desired option. A chime will sound to verify the setting. EXIT PROGRAMMING Continue with the following steps in order to exit the programming mode: 1. Press the SEEK button to scroll to the end of the MAIN MENU until EXIT is displayed. 2. Press the DISP button to exit the MAIN MENU. PROGRAMMING FEATURES WITH THE TECH 2 To enter programming with the Tech 2, perform the following actions: 1. Install the scan tool. 2. Turn ON the ignition with the engine OFF. 3. Select the correct vehicle and model year. 4. Select Body. 5. Select Personalization. DELAYED HEADLAMP ILLUMINATION Continue with the following steps in order to program the Delayed Headlamp Illumination feature: 1. Select Set Options. 2. Select F0 for Delayed Headlamp Illumination mode. 3. Highlight the desired mode from the following choices: - Mode 1: OFF - Mode 2: 30 seconds - Mode 3: 60 seconds 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. AUTOMATIC DOOR LOCK Continue with the following steps in order to program the Automatic Door Lock feature: 1. Select Set Options. 2. Select F1 for Automatic Door Lock Mode. 3. Highlight the desired mode for the following choices: - OFF - ADL out of Park - Unlock Drivers Door Only - Unlock All Doors 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. REMOTE VISUAL VERIFICATION MODE Continue with the following steps in order to program the Remote Unlock Verification Mode: 1. Select Set Options. 2. Select F2 for Remote Visual Verification Mode. 3. Highlight the desired mode for the following choices: - OFF - ON 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. REMOTE AUDIBLE VERIFICATION MODE Continue with the following steps in order to program the Remote Audible Verification Mode: 1. Select Set Options. 2. Select F3 for Remote Audible Verification Mode. 3. Highlight the desired mode for the following choices: - OFF - PARTIAL Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 10289 - FULL - DRL and Horn 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. CONTENT THEFT DETERRENT Continue with the following steps in order to program the CTD (Content Theft Deterrent System): 1. Select Set Options. 2. Select F4 for CTD Program Mode. 3. Highlight the desired mode for the following choices: - OFF - ON 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. CTD SHOCK SENSOR Continue with the following steps in order to program the CTD Shock Sensor. 1. Select Set Options. 2. Select F5 for CTD Program Mode. 3. Highlight the desired mode for the following choices: - OFF - ON 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. CTD TRUNK SWITCH Continue with the following steps in order to program the CTD Trunk Switch. 1. Select Set Options. 2. Select F6 for CTD Program Mode. 3. Highlight the desired mode for the following choices: - OFF - ON 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. HORN CHIRP MODE Continue with the following steps in order to program the Horn Chirp Mode. 1. Select Set Options. 2. Select F7 for Horn Chirp Mode. 3. Highlight the desired mode for the following choices: - Short Chirp - Long Chirp 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. POLICE OPTION (RPO A98) Continue with the following steps in order to program the Police Option Mode: 1. Select Set Options. 2. Select F8 Police Option Mode. 3. Highlight the desired mode for the following choices: - NO - YES 4. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 5. Select Save Options. 6. Exit the menu. TRAP ALERT SYSTEM Continue with the following steps in order to program the Trap Alert System: 1. Select Set Options. 2. Select F9 Trap Alert System. 3. Highlight the desired mode for the following choice: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > System Information > Description and Operation > Personalization > Page 10290 4. ENABLE 5. Press the ENTER button to turn the mode ON or OFF. (You must turn the current mode OFF before you can turn another one ON.) 6. Select Save Options. 7. Exit the menu. ADDITIONAL INFORMATION For more information about the personalization features, refer to one of the following description and operations: Refer to Content Theft Deterrent (CTD) Description and Operation in Theft Deterrent for more information about the content theft deterrent features. - Refer to Power Door Locks Description and Operation in Doors for more information about the automatic door lock feature. - Refer to Interior Lighting Systems Description and Operation in Lighting Systems for more information about the delayed headlamp illumination feature. - Refer to Keyless Entry System Description and Operation in Keyless Entry for more information about remote activation verification. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Drive Cable > Component Information > Service and Repair > Drive Cable Replacement - Horizontal Power Seat Drive Cable: Service and Repair Drive Cable Replacement - Horizontal Drive Cable Replacement - Horizontal Removal Procedure 1. If the seat is equipped with a driver side air bag, disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. 2. If one side of the seat adjuster is not working, perform the following procedure: 1. The horizontal drive motor (1) and the drive cables (4) are located at the front of the seat. Verify that both cables are straight. If a cable is bent, an end will be pulled out of the drive motor or the drive screw. Straighten the cable. The seat switch may have to be toggled back and forth to get the cable ends to seat properly. 2. Run the seat forward until the seat removal bolts are accessible. 3. Remove the front seat bolts. 4. Remove the head restraint. 5. Tip the seat forward and disconnect the electrical connector from the seat electrical harness. 6. Disengage the seat hook attachments from the floor pan. 7. Tip the seat rearward to expose the horizontal drive cables (4). Important: The short cable is not replaceable. 8. Bend the long flexible cable at the center and pull the cable out of the motor and the drive screw. 9. Remove the cable from the vehicle. Installation Procedure 1. Insert the end of one cable (4) into the drive screw. 2. Bend the cable and insert the other end into the motor. Important: Examine all 4 drive cables to ensure that the cables are straight. 3. Connect the electrical connector to the seat wire harness and test the seat for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Drive Cable > Component Information > Service and Repair > Drive Cable Replacement - Horizontal > Page 10295 4. Examine the horizontal drive cables for synchronization. Refer to Seat Adjuster Phase Adjustment - Power. 5. Tip the seat forward and engage the seat hook attachments to the floor pan. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bolts that secure the adjuster to the floor pan. Tighten the bolts to 42 N.m (31 lb ft). 7. Install the head restraint. 8. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Drive Cable > Component Information > Service and Repair > Drive Cable Replacement - Horizontal > Page 10296 Power Seat Drive Cable: Service and Repair Drive Cable Replacement - Vertical Drive Cable Replacement - Vertical Removal Procedure 1. If the seat is equipped with a driver side air bag, disable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. 2. Remove the front seat bolts. 3. Remove the head restraint. 4. Tip the seat forward and disconnect the electrical connector from the seat electrical harness. 5. Disengage the seat hook attachments from the floor pan. 6. Tip the seat forward to expose the vertical drive cables (3,4). 7. To remove either cable perform the following procedure: 1. Bend the flexible cable at the center. 2. Pull the cable out of the motor (1,2) and the drive screw. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Drive Cable > Component Information > Service and Repair > Drive Cable Replacement - Horizontal > Page 10297 1. Insert the end of the replacement cable (3,4) into the drive screw. 2. Bend the cable and insert the other end into the motor (1,2). 3. If required, repeat the above procedure for the second drive cable. Important: Examine all 4 drive cables to ensure that the cables are straight. 4. Connect the electrical connector to the seat wire harness and test the seat for proper operation. 5. Tip the seat forward and engage the seat hook attachments to the floor pan. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bolts that secure the adjuster to the floor pan. Tighten the bolts to 42 N.m (31 lb ft). 7. Install the head restraint. 8. Enable the SIR system. Refer to SIR Disabling and Enabling Zone 3 in Restraint Systems. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams Power Seat Motor: Diagrams Seat Adjuster Motor Assembly-Driver Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 10301 Seat Adjuster Motor Assembly-Driver Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 10302 Seat Adjuster Motor Assembly-Front Passenger Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 10303 Seat Adjuster Motor Assembly-Front Passenger Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Diagrams > Page 10304 Power Seat Motor: Adjustments Seat Adjuster Phase Adjustment - Power 1. Disable the SIR. Refer to SIR Disabling and Enabling Zone 5 in Restraint Systems. 2. Using the power seat switch, run the seat adjuster rearward until the drive bracket (3) and the anchor bracket (2) are together on either side of the adjuster. 3. Remove the drive cable (4) from the side of the adjuster which contains the brackets that touch. 4. Use the power seat switch to run the adjuster rearward until the other pair of brackets are together. 5. Install the removed drive cable. Important: Inspect all 4 cables to verify that the cables are straight. 6. Test the adjuster for proper operation. 7. Enable the SIR. Refer to SIR Disabling and Enabling Zone 5 in Restraint Systems. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Lumbar Replacement - Front Seat Power Seat Motor: Service and Repair Lumbar Replacement - Front Seat Lumbar Replacement - Front Seat Important: The front seat power and/or manual lumbar assembly is not serviced as a separate part of the front seat back frame. If the front seat power and/or manual lumbar assembly replacement is necessary, the entire seat back frame must be replaced. Refer to Seat Back Frame Replacement - Front. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Lumbar Replacement - Front Seat > Page 10307 Power Seat Motor: Service and Repair Seat Adjuster Replacement - Front Seat Adjuster Replacement - Front Removal Procedure 1. If one side of the seat adjuster is not working, perform the following procedure: 1. The horizontal drive motor (1) and drive cables (4) are located at the front of the seat. Check to see if both cables are straight. If a cable is bent an end will be pulled out of the drive motor or drive screw. Straighten the cable. The seat switch may have to he toggled back and forth to get the cable ends to properly seat. 2. Run the seat forward until the seat removal bolts are accessible. 3. Once the seat is removed the cables must be removed and examined to assure that no damage has occurred. 4. Also, the two sides of the seat adjuster will now be out of sync and must be readjusted or the adjuster may be noisy and the motor may overheat and fail. Use the following steps for adjustment. - Tip the seat rearward. - Reconnect the adjuster to the power switch. - Run the seat adjuster rearward until the drive bracket (3) and the anchor bracket (2) are together on one side of the adjuster. - Disconnect the drive cable on that side and run the opposite side rearward until its brackets touch. - Re-attach the cable (4) to the motor and make sure they are straight between the motor (1) and the drive brackets (3). 2. If the power seat motor is not operable, and the bolts that secure the adjuster to the floor pan are not accessible, perform the following procedure: * From the front of the seat, disconnect both drive cables at the horizontal drive motor (2), which is located at the front of the seat adjuster. * Attach a drill motor to a drive cable (1). * Alternately run both sides of the adjuster forward until the seat removal bolts are accessible. 3. Remove the front seat. 4. Remove the seat trim panel. 5. Remove the seat belt bracket (2) on the door side of the seat. The new adjuster does not have this part. 6. Remove the seat belt buckle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Lumbar Replacement - Front Seat > Page 10308 7. Remove the electrical harness from the power seat motor harness. 8. Remove the electrical harness clip and disconnect the harness retainer from the adjuster bracket. 9. Recline the seat back to the full reclined position. 10. Remove the trim cover J-hooks from the seat front and from the seat sides. 11. Fold back the seat trim and the pad to access the adjuster bolts. 12. Remove the 4 adjuster bolts. 13. Remove the seat adjuster. Installation Procedure 1. Position the adjuster on the seat frame. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Service and Repair > Lumbar Replacement - Front Seat > Page 10309 2. Install the adjuster bolts. Tighten the bolts to 24 N.m (18 lb ft). 3. Return the seat pad and the trim to the installed position. 4. Install the trim cover J-hooks. 5. Install the electrical harness clip and the retainer on the adjuster bracket. 6. Connect the electrical harness to the seat motor harness. 7. Install the seat belt buckle. 8. Install the seat belt bracket (2). 9. Install the seat trim panel. Important: Inspect the drive cables. Make sure they are straight between the motors and the adjuster. 10. Install the front seat. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations Power Seat Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 10313 Power Seat Switch: Diagrams Seat Adjuster Switch-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 10314 Seat Adjuster Switch-Front Passenger Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Locations > Page 10315 Seat Adjuster Switch-Front Passenger Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Procedures Power Seat Switch: Procedures Lumbar Switch Replacement LUMBAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the outer seat cushion trim panel. 2. Remove the screws from the lumbar control switch. 3. Remove the lumbar control switch from the outer seat cushion trim panel. INSTALLATION PROCEDURE 1. Position the lumbar control switch to the outer seat cushion trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws (1) to the lumbar control switch. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the outer seat cushion trim panel. Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE 1. Remove the front seat cushion outer trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 10318 2. Remove the power front seat switch from the front seat outer trim panel, using a small flat bladed tool. 3. Disconnect the electrical connector from the power front seat switch. 4. Remove the power front seat switch from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power front seat switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 10319 2. Install the power front seat switch to the front seat outer trim panel, pressing into place until fully seated. 3. Install the front seat cushion outer trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 10320 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Seat Switch Replacement - Power Removal Procedure 1. Remove the front seat cushion outer trim panel. 2. Remove the power front seat switch from the front seat outer trim panel, using a small flat bladed tool. 3. Disconnect the electrical connector from the power front seat switch. 4. Remove the power front seat switch from the vehicle. Installation Procedure 1. Connect the electrical connector to the power front seat switch. 2. Install the power front seat switch to the front seat outer trim panel, pressing into place until fully seated. 3. Install the front seat cushion outer trim panel. Lumbar Switch Replacement Lumbar Switch Replacement Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 10321 Removal Procedure 1. Remove the outer seat cushion trim panel. 2. Remove the screws from the lumbar control switch. 3. Remove the lumbar control switch from the outer seat cushion trim panel. Installation Procedure 1. Position the lumbar control switch to the outer seat cushion trim panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws (1) to the lumbar control switch. Tighten the screws to 2 N.m (18 lb in). 3. Install the outer seat cushion trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front Seat Back Frame: Service and Repair Seat Back Frame Replacement - Front SEAT BACK FRAME REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the front seat back. 2. Remove the front seat back pad from the front seat back frame. 3. Remove the inflatable restraint front side impact module, if equipped. INSTALLATION PROCEDURE 1. Install the inflatable restraint front side impact module, if equipped. 2. Install the front seat back pad to the front seat back frame. 3. Install the front seat back. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 10327 Seat Back Frame: Service and Repair Seat Back Frame Replacement - Rear (Fold Down) SEAT BACK FRAME REPLACEMENT - REAR (FOLD DOWN) REMOVAL PROCEDURE 1. Remove the rear seat back. 2. Remove the rear seat back bolsters. 3. Remove the seat back pivot bolts (1) from the seat back frame. 4. Remove the seat backs from the seat back frame. INSTALLATION PROCEDURE 1. Position the fold down seat backs on the rear seat back frame. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 10328 NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the seat back frame pivot bolts (1). Tighten Tighten the bolts to 10 N.m (89 lb in). 3. Install the rear seat back bolsters. 4. Install the rear seat back. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Back > Seat Back Frame > Component Information > Service and Repair > Seat Back Frame Replacement - Front > Page 10329 Seat Back Frame: Service and Repair Seat Back Frame Replacement - Rear (Fixed) SEAT BACK FRAME REPLACEMENT - REAR (FIXED) REMOVAL PROCEDURE 1. Remove the rear seat back. 2. Remove the rear seat back pad. 3. Remove the seat back pad frame. INSTALLATION PROCEDURE 1. Install the seat back frame. 2. Install the rear seat back pad. 3. Install the rear seat back. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info Seat Cover: Technical Service Bulletins Interior - Seat Cover Wrinkle/Crease/Burn Info INFORMATION Bulletin No.: 04-08-50-006D Date: September 09, 2010 Subject: Minor Wrinkles/Creases, Discoloration, Cigarette Burns and Customer Induced Cuts and Stains on Front and Rear Driver and Passenger Seats with Leather, Vinyl or Cloth Seat Covers Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2009 and Prior Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add a model year. Please discard Corporate Bulletin Number 04-08-50-006C (Section 08 - Body and Accessories). If a customer comes in to your dealership due to certain conditions of the seat covers (splits, wrinkles, loose stitching, etc.), you must examine the seat cover in order to determine the validity of the customer claim. Some components from the above listed vehicles have been returned to the Warranty Parts Center (WPC) and analysis of these parts showed "customer induced damage" or No Trouble Found (NTF). The dealer should pay particular attention to the following conditions: - Cigarette burns Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10334 - Customer induced cuts (knife cuts, cut by customer tools, etc.) - Paint stains (customer should have cleaned paint stains while paint was still wet) - Coffee stains and other removable dirt These should be cleaned as described in the Owner's Manual under Appearance Care. Also, refer to Corporate Bulletin Number 06-00-89-029A or later. - Evidence of chemicals used for cleaning, other than those specified in the Owner's Manual - Other chemical spills - Minor and normal leather wrinkles as a result of use - Other defects to the seat cover not detected during the pre-delivery inspection (PDI). Inform the customer that the above issues were not present when the vehicle was purchased and cannot be replaced under warranty. The covers, however, may be repaired or replaced at the customer's expense. The following conditions are not caused by the customer and should be covered by warranty: - Split seams Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10335 - Wear/cracking/peeling - Discoloration/dye transfer from customer clothing (if discoloration/dye transfer is not removed after using GM Leather and Vinyl Plastic Cleaner, P/N 88861401 (in Canada, P/N 88861409), replace the covers.) Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10336 Seat Cover: Technical Service Bulletins Interior - Elimination Of Unwanted Odors INFORMATION Bulletin No.: 00-00-89-027E Date: September 29, 2008 Subject: Eliminating Unwanted Odors in Vehicles Models: 2009 and Prior GM Passenger Cars and Trucks (including Saturn) 2009 and Prior HUMMER H2, H3 Vehicles 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and refine the instructions. Please discard Corporate Bulletin Number 00-00-89-027D (Section 00 - General Information). Vehicle Odor Elimination General Motors offers a product that may control or eliminate odors in the interior and luggage compartment areas of GM vehicles. GM Vehicle Care Odor Eliminator is a non-toxic, biodegradable odor remover. This odorless product has been shown to greatly reduce or remove objectionable smells of mold and mildew resulting from vehicle water leaks (as well as customer created odors, i.e. smoke). You may use GM Vehicle Care Odor Eliminator on fabrics, vinyl, leather, carpet and sound deadening materials. It may also be induced into HVAC modules and instrument panel ducts (for the control of non-bacterial related odors). Important: This product leaves no residual scent and should not be sold as or considered an air freshener. Product action may result in the permanent elimination of an odor and may be preferable to customers with allergies who are sensitive to perfumes. How to Use This Product GM Vehicle Care Odor Eliminator may be sprayed on in a ready-to-use formula or used in steam cleaners as an additive with carpet shampoo. This water-based, odorless product is safe for all vehicle interiors. Do not wet or soak any interior surface that plain water would cause to deteriorate, as this product will have the same effect. Also avoid letting this product come into contact with vinegar or any acidic substance. Acid-based products will hamper the effectiveness of, or render GM Vehicle Care Odor Eliminator inert. Note: Complete eight page treatment sheets are enclosed within each case of GM Vehicle Care Odor Eliminator. These treatment instructions range from simple vehicle odor elimination to full step by step procedures for odor removal from water leaks. If lost, contact 800-977-4145 to get a replacement set faxed or e-mailed to your dealership. Instructions and cautions are printed on the bottle, but additional help is available. If you encounter a difficult to eliminate or reoccurring odor, you may call 1-800-955-8591 (in Canada, 1-800-977-4145) to obtain additional information and usage suggestions. Important: This product may effectively remove odors when directly contacting the odor source. It should be used in conjunction with diagnostic procedures (in cases such as a water leak) to first eliminate the root cause of the odor, and then the residual odor to permanently correct the vehicle condition. Vehicle Waterleak Odor Elimination STEP ONE: Confirm that all water leaks have been repaired. Determine what areas of the vehicle were water soaked or wet. Components with visible mold/mildew staining should be replaced. Isolate the odor source inside the vehicle. Often an odor can be isolated to an area or component of the vehicle interior by careful evaluation. Odor evaluation may need to be performed by multiple persons. Another method of isolating an odor source is to remove and segregate interior trim and components. Plastic sheeting or drop cloths can be used to confine seats, headliners, etc. to assist in evaluation and diagnoses. If appropriate the vehicle and interior trim should be evaluated separately to determine if the odor stays with the vehicle or the interior components. Odors that stay with the vehicle may be isolated to insulating and sound deadening materials (i.e. water leak at the windshield or standing water in the front foot well area caused mold/mildew to form on the bulkhead or kick panel sound deadening pads. If the interior is removed the floor pan and primed/painted surfaces should be treated with bleach/soap solution, rinsed with clean water and dried. Interior surfaces should then be treated with GM Vehicle Care Odor Eliminator product before reinstalling carpet or reassembling. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10337 The GM Vehicle Care Odor Eliminator product is an effective odor elimination product when used properly. It must come into direct contact with the odor source. It should be used in conjunction with diagnostic procedures to first eliminate the root cause of the odor. Some procedures for use after odor root cause correction are: STEP TWO: ^ Use the trigger spray head. ^ Put a drop of dish soap the size of a quarter in the bottom of a bottle. ^ Add 8 oz. of GM Vehicle Care Odor Eliminator (1 cup) to the dish soap and top off the bottle with tap water. ^ This formula should be used on hard surfaces (dash, interior plastic molding, and floor pan) STEP THREE: The third step to neutralizing the vehicle is a light to medium treatment of all carpeting and upholstered seats with the GM Vehicle Care Odor Eliminator formula and a wide fan spray setting (at full strength) (i.e.: carpeting on the driver's side requires 4-5 triggers pulls for coverage). The headliner and trunk should be sprayed next. Lightly brushing the formula into the carpeting and upholstery is a recommended step for deep odor problems. The dash and all hard surfaces should be sprayed with dish soap/water mixture. Let stand for 1-2 minutes then wipe off the surface. STEP FOUR: (vehicle ventilation system treatment) The ventilation system is generally the last step in the treatment of the vehicle. a. Spray the GM Vehicle Care Odor Eliminator formula into all dash vents. (1-2 trigger pulls per vent). b. Start the vehicle and turn the vehicle fan on high cool (not A/C setting). c. Spray the formula (10 trigger pulls) into the outside fresh air intake vent (cowl at base of windshield) d. Enter the vehicle after 1 minute and wipe off the excess formula spurting out of the dash vents. e. Smell the air coming from the dash vents. If odors are still present, spray another 5 triggers into the cowl, wait another minute and smell the results. Once you have obtained a fresh, clean smell coming from the vents, turn the system to the A/C re-circulation setting. Roll up the windows, spray 3-5 pumps into the right lower IP area and let the vehicle run with the fan set on high for 5-7 minutes. Please follow this diagnosis process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed. If these steps do not resolve the condition, please contact GM TAC for further diagnostic assistance. Additional Suggestions to Increase Customer Satisfaction Here are some additional ideas to benefit your dealership and to generate greater customer enthusiasm for this product. ^ Keep this product on-hand for both the Service Department and the Used Car lot. Add value to your used car trades; treat loaner and demo cars during service and at final sale to eliminate smoke, pet, and other common odors offensive to customers. Make deodorizing a vehicle part of your normal vehicle detailing service. ^ Consider including GM Vehicle Care Odor Eliminator as a give-away item with new vehicle purchases. Many dealers give away as "gifts" various cleaning supplies at time of delivery. GM Odor Eliminator is one of a few products GM offers that has as many uses in the home as in the vehicle. Customers may find this product can be used for a host of recreational activities associated with their new vehicle, such as deodorizing a boat they tow, or a camper. ^ GM Odor Eliminator and many of the GM Vehicle Care products offer you the chance to increase dealership traffic as these superior quality products cannot be purchased in stores. Many Dealerships have product displays at the parts counter. Consider additional displays in the Customer Service Lounge, the Showroom and at the Service Desk or Cashier Window. Many customers who purchase vehicles and receive regular maintenance at your dealership may never visit the parts counter, and subsequently are not exposed to the variety and value that these products offer. Parts Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Interior - Seat Cover Wrinkle/Crease/Burn Info > Page 10338 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures Seat Cushion: Procedures Seat Cushion Cover Replacement - Front (Bucket Seat) SEAT CUSHION COVER REPLACEMENT - FRONT (BUCKET SEAT) REMOVAL PROCEDURE 1. Remove the front seat from the vehicle. 2. Remove the front seat trim panel. 3. Remove the front seat outer trim bracket. 4. Disconnect the electrical connector for the heated seat, if equipped. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10343 5. Unfasten the J-hook retainers on all sides of the front seat cushion cover. 6. Unfasten the side J-hook retainers located at the seat back. 7. Fold the seat back down to a horizontal position. 8. Unfasten the hook and the loop retainers securing the seat cushion cover to the cushion. 9. If the vehicle is equipped with heated seats, pull the seat heater electric line up through the foam cushion. 10. Pull the trim and cushion foam from under the seat back. 11. Remove the hog rings from the rear of the front seat cushion cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10344 12. Remove the front seat cushion cover from the front seat cushion. INSTALLATION PROCEDURE 1. Align the front seat cushion cover to the front seat cushion. 2. If the vehicle is equipped with heated seats, pass the electric line through the seat cushion. 3. Install the hog rings to the rear of the front seat cushion cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10345 4. Install the seat cushion cover onto the front seat cushion. 5. Fasten the hook and the loop retainers securing the seat cushion cover to the cushion, by pressing in place until fully seated. 6. Push the seat trim and cushion under the seat back. 7. Fasten the J-hook retainers on all sides of the front seat cushion cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10346 8. Connect the electrical connector for the heated seat, if equipped. 9. Install the front seat outer trim bracket. 10. Install the front seat trim panel. 11. Install the front seat to the vehicle. Seat Cushion Cover Replacement - Front (Split Bench) SEAT CUSHION COVER REPLACEMENT - FRONT (SPLIT BENCH) REMOVAL PROCEDURE 1. Remove the front seat from the vehicle. 2. Remove the front seat armrest from the front seat. 3. Remove the front seat back. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10347 4. Remove the front seat outer trim bracket. 5. Disconnect the electrical connector for the heated seat, if equipped. 6. Unfasten the J-hook retainers on all sides of the front seat cushion cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10348 7. Unfasten the retainers from the seat frame on the bottom of the front seat cushion. 8. Unfasten the retainer from the front seat frame at the seat belt. 9. Remove the hog rings from the rear of the front seat cushion cover. 10. Unfasten the hook and the loop retainers securing the front seat cushion cover to the cushion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10349 11. Remove the front seat cushion cover from the front seat cushion. 12. Remove the J-hook retainers from the front seat frame, if required. INSTALLATION PROCEDURE 1. Install the J-hook retainers to the front seat frame, if required. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10350 2. Align the front seat cushion cover to the front seat cushion. 3. Install the front seat cushion cover onto the front seat cushion. 4. Install the hog rings to the rear of the front seat cushion cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10351 5. Fasten the J-hook retainers on all sides of the front seat cushion cover. 6. Fasten the retainers to the front seat frame on the bottom of the front seat cushion. 7. Fasten the retainer to the front seat frame at the seat belt. 8. Fasten the hook and the loop retainers securing the front seat cushion cover to the cushion, by pressing in place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10352 9. Connect the electrical connector for the heated seat, if equipped. 10. Install the front seat outer trim bracket. 11. Install the front seat armrest from the front seat. 12. Install the front seat back. 13. Install the front seat to the vehicle. Seat Cushion Cover Replacement - Rear SEAT CUSHION COVER REPLACEMENT - REAR REMOVAL PROCEDURE 1. Remove the rear seat cushion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10353 2. Remove the hog rings from the rear seat cushion cover. 3. Reach inside of the rear seat cushion cover in order to unfasten the hook and the loop retainers securing the rear seat cushion cover to the pad. 4. Remove the rear seat cushion cover from the pad. INSTALLATION PROCEDURE 1. Position the rear seat cushion cover to the pad. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10354 2. Align the alignment marks on the rear seat cushion cover to the alignment marks on the pad. 3. Pull the rear seat cushion cover over the pad and aline the hook and the loop retainers. 4. Pull the rear seat cushion cover over the pad and pull over and under the edge. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10355 5. Use firm hand pressure in order to fasten the hook and the loop retainers, securing the rear seat cushion cover to the pad. 6. Align the alignment marks on the rear seat cushion cover to the alignment marks on the pad, on the back side. 7. Install the hog rings to the rear seat cushion cover. 8. Install the rear seat cushion. Seat Cushion Replacement - Front SEAT CUSHION REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the front seat from the vehicle. 2. Remove the front seat cushion cover from the front seat cushion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10356 3. Remove the hog rings from the front seat cushion cover. 4. Remove the front seat cushion from the front seat frame. INSTALLATION PROCEDURE 1. Position the front seat cushion to the front seat frame. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10357 2. Install the hog rings to the front seat cushion cover. 3. Install the front seat cushion cover to the front seat cushion. 4. Install the front seat to the vehicle. Seat Cushion Frame Replacement - Front SEAT CUSHION FRAME REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the front seat from the vehicle. 2. Remove the front seat back from the front seat. 3. Remove the front seat cushion cover from the front seat cushion. 4. Remove the front seat cushion from the front seat frame. 5. Remove the front seat recliner assembly from the front seat cushion frame. 6. Remove the bolts from the front seat cushion frame to the front seat track adjusters. 7. Remove the front seat frame from the front seat track adjusters. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10358 8. For split bench, remove the bolts from the front seat frame to the front seat track adjusters. 9. Remove the front seat cushion frame from the front seat track adjusters. INSTALLATION PROCEDURE 1. Position the front seat cushion frame to the front seat adjusters. 2. Install the bolts to the seat cushion frame to the front seat track adjusters. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10359 3. For split bench, install the bolts to the front seat frame to the front seat track adjusters. Tighten Tighten the bolts to the front seat frame to 25 N.m (18 lb ft). 4. Install the front seat recliner assembly to the front seat cushion frame. 5. Install the front seat cushion to the front seat cushion frame. 6. Install the front seat cushion cover to the front seat cushion. 7. Install the front seat back to the front seat. 8. Install the front seat to the vehicle. Seat Cushion Replacement - Rear SEAT CUSHION REPLACEMENT - REAR REMOVAL PROCEDURE Remove the rear seat cushion by lifting up and pulling out of the retainer. If the retainer comes out with the cushion, remove the retainer and press the retainer back into the floor pan. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10360 1. Align the seat belts to the notches in the rear seat cushion. 2. Position the cushion to the retainers. 3. Press down to install the cushion to the retainers. 4. Inspect the cushion for proper installation. Seat Cushion Retainer Replacement - Rear SEAT CUSHION RETAINER REPLACEMENT - REAR REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10361 1. Remove the rear seat cushion. 2. Use a flat-bladed tool to release the retainers from the floor. Slide the tool under the front edge and pry up. INSTALLATION PROCEDURE 1. Install the retainers into the floor, pressing in until fully seated. 2. Install the rear seat cushion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10362 Seat Cushion: Removal and Replacement Seat Cushion Cover Replacement - Front (Bucket Seat) Seat Cushion Cover Replacement - Front (Bucket Seat) Removal Procedure 1. Remove the front seat from the vehicle. 2. Remove the front seat trim panel. 4. Disconnect the electrical connector for the heated seat, if equipped. 5. Unfasten the J-hook retainers on all sides of the front seat cushion cover. 6. Unfasten the side J-hook retainers located at the seat back. 7. Fold the seat back down to a horizontal position. 8. Unfasten the hook and the loop retainers securing the seat cushion cover to the cushion. 9. If the vehicle is equipped with heated seats, pull the seat heater electric line up through the foam cushion. 10. Pull the trim and cushion foam from under the seat back. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10363 11. Remove the hog rings from the rear of the front seat cushion cover. 12. Remove the front seat cushion cover from the front seat cushion. Installation Procedure 1. Align the front seat cushion cover to the front seat cushion. 2. If the vehicle is equipped with heated seats, pass the electric line through the seat cushion. 3. Install the hog rings to the rear of the front seat cushion cover. 4. Install the seat cushion cover onto the front seat cushion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10364 5. Fasten the hook and the loop retainers securing the seat cushion cover to the cushion, by pressing in place until fully seated. 6. Push the seat trim and cushion under the seat back. 7. Fasten the J-hook retainers on all sides of the front seat cushion cover. 8. Connect the electrical connector for the heated seat, if equipped. 9. Install the front seat outer trim bracket. 10. Install the front seat trim panel. 11. Install the front seat to the vehicle. Seat Cushion Cover Replacement - Front (Split Bench) Seat Cushion Cover Replacement - Front (Split Bench) Removal Procedure 1. Remove the front seat from the vehicle. 2. Remove the front seat armrest from the front seat. 3. Remove the front seat back. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10365 4. Remove the front seat outer trim bracket. 5. Disconnect the electrical connector for the heated seat, if equipped. 6. Unfasten the J-hook retainers on all sides of the front seat cushion cover. 7. Unfasten the retainers from the seat frame on the bottom of the front seat cushion. 8. Unfasten the retainer from the front seat frame at the seat belt. 9. Remove the hog rings from the rear of the front seat cushion cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10366 10. Unfasten the hook and the loop retainers securing the front seat cushion cover to the cushion. 11. Remove the front seat cushion cover from the front seat cushion. 12. Remove the J-hook retainers from the front seat frame, if required. Installation Procedure 1. Install the J-hook retainers to the front seat frame, if required. 2. Align the front seat cushion cover to the front seat cushion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10367 3. Install the front seat cushion cover onto the front seat cushion. 4. Install the hog rings to the rear of the front seat cushion cover. 5. Fasten the J-hook retainers on all sides of the front seat cushion cover. 6. Fasten the retainers to the front seat frame on the bottom of the front seat cushion. 7. Fasten the retainer to the front seat frame at the seat belt. 8. Fasten the hook and the loop retainers securing the front seat cushion cover to the cushion, by pressing in place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10368 9. Connect the electrical connector for the heated seat, if equipped. 10. Install the front seat outer trim bracket. 11. Install the front seat armrest from the front seat. 12. Install the front seat back. 13. Install the front seat to the vehicle. Seat Cushion Frame Replacement - Front Seat Cushion Frame Replacement - Front Removal Procedure 1. Remove the front seat from the vehicle. 2. Remove the front seat back from the front seat. 3. Remove the front seat cushion cover from the front seat cushion. 4. Remove the front seat cushion from the front seat frame. 5. Remove the front seat recliner assembly from the front seat cushion frame. 6. Remove the bolts from the front seat cushion frame to the front seat track adjusters. 7. Remove the front seat frame from the front seat track adjusters. 8. For split bench, remove the bolts from the front seat frame to the front seat track adjusters. 9. Remove the front seat cushion frame from the front seat track adjusters. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10369 1. Position the front seat cushion frame to the front seat adjusters. 2. Install the bolts to the seat cushion frame to the front seat track adjusters. Notice: Refer to Fastener Notice in Service Precautions. 3. For split bench, install the bolts to the front seat frame to the front seat track adjusters. Tighten the bolts to the front seat frame to 25 N.m (18 lb ft). 4. Install the front seat recliner assembly to the front seat cushion frame. 5. Install the front seat cushion to the front seat cushion frame. 6. Install the front seat cushion cover to the front seat cushion. 7. Install the front seat back to the front seat. 8. Install the front seat to the vehicle. Seat Cushion Replacement - Front Seat Cushion Replacement - Front Removal Procedure 1. Remove the front seat from the vehicle. 2. Remove the front seat cushion cover from the front seat cushion. 3. Remove the hog rings from the front seat cushion cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10370 4. Remove the front seat cushion from the front seat frame. Installation Procedure 1. Position the front seat cushion to the front seat frame. 2. Install the hog rings to the front seat cushion cover. 3. Install the front seat cushion cover to the front seat cushion. 4. Install the front seat to the vehicle. Seat Cushion Replacement - Rear Seat Cushion Replacement - Rear Removal Procedure Remove the rear seat cushion by lifting up and pulling out of the retainer. If the retainer comes out with the cushion, remove the retainer and press the retainer back into the floor pan. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10371 1. Align the seat belts to the notches in the rear seat cushion. 2. Position the cushion to the retainers. 3. Press down to install the cushion to the retainers. 4. Inspect the cushion for proper installation. Seat Cushion Cover Replacement - Rear Seat Cushion Cover Replacement - Rear Removal Procedure 1. Remove the rear seat cushion. 2. Remove the hog rings from the rear seat cushion cover. 3. Reach inside of the rear seat cushion cover in order to unfasten the hook and the loop retainers securing the rear seat cushion cover to the pad. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10372 4. Remove the rear seat cushion cover from the pad. Installation Procedure 1. Position the rear seat cushion cover to the pad. 2. Align the alignment marks on the rear seat cushion cover to the alignment marks on the pad. 3. Pull the rear seat cushion cover over the pad and aline the hook and the loop retainers. 4. Pull the rear seat cushion cover over the pad and pull over and under the edge. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10373 5. Use firm hand pressure in order to fasten the hook and the loop retainers, securing the rear seat cushion cover to the pad. 6. Align the alignment marks on the rear seat cushion cover to the alignment marks on the pad, on the back side. 7. Install the hog rings to the rear seat cushion cover. 8. Install the rear seat cushion. Seat Cushion Retainer Replacement - Rear Seat Cushion Retainer Replacement - Rear Removal Procedure 1. Remove the rear seat cushion. 2. Use a flat-bladed tool to release the retainers from the floor. Slide the tool under the front edge and pry up. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Cushion > Component Information > Service and Repair > Procedures > Page 10374 1. Install the retainers into the floor, pressing in until fully seated. 2. Install the rear seat cushion. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams Seat Heater: Diagrams Heated Seat Element-Driver Back Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 10378 Heated Seat Element-Front Passenger Back Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 10379 Heated Seat Element-Driver Cushion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 10380 Heated Seat Element-Front Passenger Cushion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Diagrams > Page 10381 Seat Heater: Description and Operation HEATED SEATS DESCRIPTION AND OPERATION HEATED SEAT SYSTEM COMPONENTS The heated seat system consists of the following components: Driver heated seat control module - Driver heated seat switch - Driver seat back heater element - Driver seat cushion heater element - Passenger heated seat control module - Passenger heated seat switch - Passenger seat back heater element - Passenger seat cushion heater element - LH HTD ST/BCM 15A fuse - RH HTD SEAT 15A fuse HEATED SEAT SYSTEM CONTROLS The heated seat system is controlled by the following components: Body control module - Driver heated seat control module - Driver heated seat switch - Passenger heated seat control module - Passenger heated seat switch HEATED SEAT SYSTEM DESCRIPTION The heated seat control module controls the battery positive voltage used to supply the seat heater elements. Voltage is supplied to the heated seat switch from the body control module. When the heated seat switch is in the high or low position voltage is supplied through the on switch signal circuit to the heated seat control module. Voltage to the high/low switch signal circuit is reduced by the resistors within the heated seat switch, high or low seat heater operation is determined by the voltage level to the heated seat control module. The heated seat control module uses the resistance through the heated seat thermistor to regulate the seat temperature. When the heated seat reaches the maximum temperature for high or low operating modes the battery positive voltage supply to the seat heater elements is removed. When the seat cools the resistance value through the heated seat thermistor returns to the limits set for high or low heated seat operation and the heated seat control module provides the battery positive voltage supply to the heated seat element supply circuit. The body control module controls the voltage supply circuit to the heated seat switch for the purpose of load management control. The load management control feature allows the body control module to reduce the load on the vehicles charging system when inputs to the powertrain control module indicate the demand is greater than the generator is able to supply. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Procedures Seat Heater: Procedures SEAT HEATER ELEMENT REPLACEMENT - FRONT 1. The seat heating element is sewn into the front seat back cover and the front seat cushion cover. 2. The seat heating element must be serviced as a unit. Refer to the following procedures for replacement: - For the front seat back cover, refer to Seat Back Cover Replacement - Front. - For the front seat cushion cover, refer to Seat Cushion Cover Replacement - Front (Bucket Seat)Seat Cushion Cover Replacement - Front (Split Bench). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Service and Repair > Procedures > Page 10384 Seat Heater: Removal and Replacement Seat Heater Element Replacement - Front 1. The seat heating element is sewn into the front seat back cover and the front seat cushion cover. 2. The seat heating element must be serviced as a unit. Refer to the following procedures for replacement: * For the front seat back cover, refer to Seat Back Cover Replacement - Front. * For the front seat cushion cover, refer to Seat Cushion Cover Replacement - Front (Bucket Seat) Seat Cushion Cover Replacement - Front (Split Bench). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Procedures Seat Heater Control Module: Procedures HEATED SEAT CONTROL MODULE REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Position the seat to the full-up position. 2. Remove the bolts that secure the front seat frame to the floor. 3. Rotate the seat forward to access the heater module. 4. Disconnect the seat electrical harness connector. 5. Disconnect the heater control module from the seat frame by sliding the control module toward the front of the seat. 6. Disconnect the electric harness connector (1) from the heater module (2). 7. Remove the heater module from the front seat. INSTALLATION PROCEDURE 1. Position the heater module to the front seat. 2. Connect the electrical harness connector (1) to the heater module (2). 3. Position the module on the frame and slide the module rearward until the module locks into place. 4. Lower the seat. 5. Connect the seat electrical harness connector. NOTE: Refer to Fastener Notice in Service Precautions. 6. Install the bolts that secure the front bucket seat adjuster to the floor pan. Tighten Tighten the bolts to 42 N.m (31 lb ft). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Procedures > Page 10389 7. Reposition the front seat to the original position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information > Service and Repair > Procedures > Page 10390 Seat Heater Control Module: Removal and Replacement Heated Seat Control Module Replacement - Front Removal Procedure 1. Position the seat to the full-up position. 2. Remove the bolts that secure the front seat frame to the floor. 3. Rotate the seat forward to access the heater module. 4. Disconnect the seat electrical harness connector. 5. Disconnect the heater control module from the seat frame by sliding the control module toward the front of the seat. 6. Disconnect the electrical harness connector (1) from the heater module (2). 7. Remove the heater module from the front seat. Installation Procedure 1. Position the heater module to the front seat. 2. Connect the electrical harness connector (1) to the heater module (2). 3. Position the module on the frame and slide the module rearward until the module locks into place. 4. Lower the seat. 5. Connect the seat electrical harness connector. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the bolts that secure the front bucket seat adjuster to the floor pan. Tighten the bolts to 42 N.m (31 lb ft). 7. Reposition the front seat to the original position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Diagrams Seat Heater Relay: Diagrams Heated Seat Relay-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Relay > Component Information > Diagrams > Page 10394 Heated Seat Relay-Front Passenger Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations Power Seat Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 10398 Seat Heater Switch: Diagrams Heated Seat Switch-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Locations > Page 10399 Heated Seat Switch-Front Passenger Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Procedures Seat Heater Switch: Procedures HEATED SEAT SWITCH REPLACEMENT - FRONT (IMPALA) REMOVAL PROCEDURE 1. Remove the front seat cushion outer trim panel. 2. Disconnect the electrical connector from the front seat wiring harness. 3. Remove the front seat heated seat switch, using a small, flat-bladed tool to release the retainer clips. 4. Remove the front seat heated seat switch from the front seat cushion outer trim panel. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Procedures > Page 10402 1. Install the front seat heated seat switch to the front seat cushion outer trim panel, pressing into place until fully seated. 2. Connect the electrical connector to the front seat wiring harness. 3. Install the front seat cushion outer trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Procedures > Page 10403 Seat Heater Switch: Removal and Replacement Heated Seat Switch Replacement - Front (Impala) Removal Procedure 1. Remove the front seat cushion outer trim panel. 2. Disconnect the electrical connector from the front seat wiring harness. 3. Remove the front seat heated seat switch, using a small, flat-bladed tool to release the retainer clips. 4. Remove the front seat heated seat switch from the front seat cushion outer trim panel. Installation Procedure 1. Install the front seat heated seat switch to the front seat cushion outer trim panel, pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Service and Repair > Procedures > Page 10404 2. Connect the electrical connector to the front seat wiring harness. 3. Install the front seat cushion outer trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Diagrams Door Lock Cylinder Switch: Diagrams Door Lock Cylinder Switch-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Door Lock Cylinder Switch > Component Information > Diagrams > Page 10409 Door Lock Cylinder Switch-Front Passenger (If Equipped) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations Front Door Trim-Typical Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 10413 Power Door Lock Switch: Diagrams Door Lock Switch-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 10414 Door Lock Switch-Front Passenger Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 10415 Power Door Lock Switch: Description and Operation POWER DOOR LOCK SWITCHES The power door lock switches are used to either arm or disarm the CTD system. Pressing the lock position will cause the CTD to arm after all doors are closed and the 30 second delay period has elapsed. Pressing the unlock position will disarm the CTD system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 10416 Power Door Lock Switch: Service and Repair POWER DOOR LOCK SWITCH REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Remove the inside door handle bezel. 2. Remove the power door lock switch from the inside door handle bezel using a small, flat-bladed tool in order to release the retainers. 3. Disconnect the electrical connector from the power door lock switch. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Locations > Page 10417 1. Install the power door lock switch to the inside door handle bezel pressing into place until fully seated. 2. Connect the electrical connector to the power door lock switch. 3. Install the inside door handle bezel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Front Of Driver Door Trim (Mirrors) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10421 Power Mirror Switch: Diagrams Outside Rearview Mirror Switch Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations > Page 10422 Outside Rearview Mirror Switch Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Procedures Power Mirror Switch: Procedures POWER MIRROR SWITCH REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Remove the front door pull cup from the front door inner trim panel. 2. Disconnect the electrical connectors from the power mirror switch. 3. Remove the power mirror switch from the front door pull cup, using a small flat-bladed tool at the side of the mirror switch in order to release the mirror control switch retainer. 4. Remove the power mirror switch from the front door pull cup. INSTALLATION PROCEDURE 1. Install the power mirror switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the power mirror switch. 3. Install the front door pull cup to the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Service and Repair > Procedures > Page 10425 Power Mirror Switch: Removal and Replacement Power Mirror Switch Replacement (Impala) Removal Procedure 1. Remove the front door pull cup from the front door inner trim panel. 2. Disconnect the electrical connectors from the power mirror switch. 3. Remove the power mirror switch from the front door pull cup, using a small flat-bladed tool at the side of the mirror switch in order to release the mirror control switch retainer. 4. Remove the power mirror switch from the front door pull cup. Installation Procedure 1. Install the power mirror switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the power mirror switch. 3. Install the front door pull cup to the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations Power Seat Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 10429 Power Seat Switch: Diagrams Seat Adjuster Switch-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 10430 Seat Adjuster Switch-Front Passenger Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Locations > Page 10431 Seat Adjuster Switch-Front Passenger Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures Power Seat Switch: Procedures Lumbar Switch Replacement LUMBAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the outer seat cushion trim panel. 2. Remove the screws from the lumbar control switch. 3. Remove the lumbar control switch from the outer seat cushion trim panel. INSTALLATION PROCEDURE 1. Position the lumbar control switch to the outer seat cushion trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the screws (1) to the lumbar control switch. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the outer seat cushion trim panel. Seat Switch Replacement - Power SEAT SWITCH REPLACEMENT - POWER REMOVAL PROCEDURE 1. Remove the front seat cushion outer trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 10434 2. Remove the power front seat switch from the front seat outer trim panel, using a small flat bladed tool. 3. Disconnect the electrical connector from the power front seat switch. 4. Remove the power front seat switch from the vehicle. INSTALLATION PROCEDURE 1. Connect the electrical connector to the power front seat switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 10435 2. Install the power front seat switch to the front seat outer trim panel, pressing into place until fully seated. 3. Install the front seat cushion outer trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 10436 Power Seat Switch: Removal and Replacement Seat Switch Replacement - Power Seat Switch Replacement - Power Removal Procedure 1. Remove the front seat cushion outer trim panel. 2. Remove the power front seat switch from the front seat outer trim panel, using a small flat bladed tool. 3. Disconnect the electrical connector from the power front seat switch. 4. Remove the power front seat switch from the vehicle. Installation Procedure 1. Connect the electrical connector to the power front seat switch. 2. Install the power front seat switch to the front seat outer trim panel, pressing into place until fully seated. 3. Install the front seat cushion outer trim panel. Lumbar Switch Replacement Lumbar Switch Replacement Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch > Component Information > Service and Repair > Procedures > Page 10437 Removal Procedure 1. Remove the outer seat cushion trim panel. 2. Remove the screws from the lumbar control switch. 3. Remove the lumbar control switch from the outer seat cushion trim panel. Installation Procedure 1. Position the lumbar control switch to the outer seat cushion trim panel. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the screws (1) to the lumbar control switch. Tighten the screws to 2 N.m (18 lb in). 3. Install the outer seat cushion trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations Inside Rear Compartment Lid Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations > Page 10441 Rear Compartment Lid Ajar Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations Power Seat Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 10445 Seat Heater Switch: Diagrams Heated Seat Switch-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Locations > Page 10446 Heated Seat Switch-Front Passenger Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Procedures Seat Heater Switch: Procedures HEATED SEAT SWITCH REPLACEMENT - FRONT (IMPALA) REMOVAL PROCEDURE 1. Remove the front seat cushion outer trim panel. 2. Disconnect the electrical connector from the front seat wiring harness. 3. Remove the front seat heated seat switch, using a small, flat-bladed tool to release the retainer clips. 4. Remove the front seat heated seat switch from the front seat cushion outer trim panel. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Procedures > Page 10449 1. Install the front seat heated seat switch to the front seat cushion outer trim panel, pressing into place until fully seated. 2. Connect the electrical connector to the front seat wiring harness. 3. Install the front seat cushion outer trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Procedures > Page 10450 Seat Heater Switch: Removal and Replacement Heated Seat Switch Replacement - Front (Impala) Removal Procedure 1. Remove the front seat cushion outer trim panel. 2. Disconnect the electrical connector from the front seat wiring harness. 3. Remove the front seat heated seat switch, using a small, flat-bladed tool to release the retainer clips. 4. Remove the front seat heated seat switch from the front seat cushion outer trim panel. Installation Procedure 1. Install the front seat heated seat switch to the front seat cushion outer trim panel, pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch > Component Information > Service and Repair > Procedures > Page 10451 2. Connect the electrical connector to the front seat wiring harness. 3. Install the front seat cushion outer trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Locations Sunroof Subsystem Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Sunroof Switch (Without RPO Code U68) Sunroof Switch (Without RPO Code U68) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Sunroof Switch (Without RPO Code U68) > Page 10457 Sunroof Opening Position Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Diagrams > Page 10458 Sunroof / Moonroof Switch: Description and Operation SUNROOF OPENING POSITION SWITCH The Sunroof Opening Position Switch tracks the position of the glass through 2 limit switches: - Soft Stop limit - Vent limit The sunroof control module monitors the limit switches and based on the inputs determines the position of the sunroof glass. As a limit switch closes, the 5 volt reference will be shorted to the sunroof limit switch low reference circuit, pulling the 5 volt reference to 0 volts. The sunroof control module understands the position of the sunroof glass based on the different input combinations through the soft stop and vent limit switch inputs. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch Replacement (w/o Overhead Console) Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (w/o Overhead Console) Sunroof Switch Replacement (w/o Overhead Console) Removal Procedure 1. Grasp the power sunroof switch on the left and right sides. Important: The switch must be rotated, pulled down on the left side, to be removed. 2. Use 2, small, flat-bladed tools in order to disengage the clips which are located at the front and rear of the power sunroof switch. Hold the flat-bladed tools parallel to the roof and push straight in. 3. Rotate the power sunroof switch toward the left side to disengage it from the mounting bracket and pull down. 4. Disconnect the electrical connector from the power sunroof switch. 5. Remove the power sunroof switch from the vehicle. Installation Procedure 1. Connect the electrical connector to the power sunroof switch. 2. Rotate the power sunroof switch back into the vehicle. 3. Firmly push the power sunroof switch into the headliner until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch Replacement (w/o Overhead Console) > Page 10461 Sunroof / Moonroof Switch: Service and Repair Sunroof Switch Replacement (With Overhead Console) Sunroof Switch Replacement (With Overhead Console) Removal Procedure Important: The driver information center control module, and the power sunroof switch is serviced as a complete part. 1. Remove the overhead console. 2. Remove the driver information center control module, containing the power sunroof switch from the overhead console. Installation Procedure 1. Install the driver information center control module, containing the power sunroof switch to the overhead console. 2. Install the overhead console. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch Replacement (w/o Overhead Console) > Page 10462 Sunroof / Moonroof Switch: Service and Repair Sunroof Opening Position Switch Replacement Sunroof Opening Position Switch Replacement Tools Required J 41718 Sunroof Timing Pins Removal Procedure Important: ^ The Sunroof Opening Position Switch (SOPS) (3) is aligned to the drive cables. The switch comes from the factory set to the window panel CLOSED position. A position lock pin (1) has been installed on the top of the switch. The pin (1) must remain until after the installation of the actuator and of the switch. The lock pin locks the drive gears in place and must be removed before operation of the sunroof module. ^ If you reuse a Sunroof Opening Position Switch, place the sunroof window panel in the CLOSED position. Install the sunroof timing pins J 41718. Install a position lock pin, or install 2 wires, such as the ends of a paper clip, then remove the SOPS from the sunroof module. The SOPS timing will be lost if you do not follow this procedure. 1. Position the sunroof window panel to the closed position. 2. Remove the sunroof module from the vehicle. Important: Before removing the SOPS from the sunroof module, the J 41718 sunroof timing pins must be installed to lock the cable/cam mechanism into position. 3. The cable/cam mechanisms, on both sides of the sunroof window, contain a set of timing holes. These holes are aligned to the sunroof window panel in the CLOSED position. Remove the left and right side front sunroof window panel screws. Align the timing holes. Use a flat-bladed tool to push the cable/cam mechanism forward or rearward. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch Replacement (w/o Overhead Console) > Page 10463 Install the J 41718 sunroof timing pins into the left and right sunroof window panel screw holes. 4. Remove the sunroof actuator. 5. Disconnect the electrical connector from the SOPS (3). 6. Remove the SOPS screw (2) from the switch. 7. Hold down on both drive cables, and lift straight up to remove the SOPS from the sunroof module. Installation Procedure Important: The new SOPS comes with a position lock pin that is installed on top of the SOPS. This locks the timing gears in place. Do not remove this pin until after you have installed the SOPS and the actuator. 1. Keeping the position lock pin in the new SOPS, position the SOPS switch over the drive cables and press down. If the SOPS does not slide into position, the ridges on the drive cable housings will not go into the grooves on the back of the SOPS. Lift each cable into the SOPS, and press down on the SOPS assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Sunroof / Moonroof Switch > Component Information > Service and Repair > Sunroof Switch Replacement (w/o Overhead Console) > Page 10464 Notice: Refer to Fastener Notice in Service Precautions. 2. Install the Sunroof opening Position Switch screw (2) to the switch. Tighten Tighten the SOPS screw to 2 N.m (18 lb in). 3. Connect the electrical connector to the SOPS. 4. Install the sunroof actuator. 5. Remove the position lock pin (1) or the 2 wires from the switch. 6. Remove the 2 pins from the cable/cam mechanisms. 7. Install the left and right front sunroof window panel screws. Tighten Tighten the front sunroof window panel screws to 4 N.m (35 lb in). 8. Install the sunroof module, but do not install the headliner until after you have tested the sunroof operation. 9. Inspect the operation of the sunroof. 10. Install the headliner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Service and Repair Trunk / Liftgate Ajar Switch: Service and Repair REAR COMPARTMENT LID AJAR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Open the rear compartment. 2. Remove the rear compartment lid latch. 3. Remove the rear compartment lid ajar lamp/switch to rear compartment lid latch screw (5). 4. Remove the compartment lid ajar lamp/switch (6) from the rear compartment lid latch (8). INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Ajar Switch > Component Information > Service and Repair > Page 10468 1. Position the rear compartment lid ajar lamp/switch (6) to the rear compartment lid latch (8). NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rear compartment lid ajar lamp/switch to rear compartment lid latch screw (5). Tighten Tighten the rear compartment lid ajar lamp/switch to rear compartment lid latch screw to 5 N.m (44 lb in). 3. Install the rear compartment lid latch. 4. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Lower Left Center Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 10472 Rear Compartment Lid Release Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 10473 Trunk / Liftgate Switch: Service and Repair REAR COMPARTMENT LID SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Release the LH instrument panel (IP) insulator tabs from the lower IP trim pad retainers for access. 2. Remove the LH fuse block access cover. 3. Remove the steering column opening filler panel screws. 4. Release the steering column opening filler panel retainers from the IP lower trim panel. Carefully lower the steering column opening filler panel away from the IP lower trim panel. 5. Disconnect the electrical connector from the rear compartment release switch. 6. Remove the rear compartment release switch. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations > Page 10474 1. Install the rear compartment release switch. 2. Connect the electrical connector to the rear compartment release switch. 3. Align the steering column opening filler panel to the instrument panel (IP) lower trim panel. Install the steering column opening filler panel retainers to the IP lower trim panel. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the steering column opening filler panel screws. Tighten Tighten the steering column opening filler panel screws to 2 N.m (18 lb in). 5. Install the LH IP insulator tabs to the lower IP trim pad retainers. 6. Install the LH fuse block access cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Service and Repair Sound Proofing / Insulation: Service and Repair Fender Sound Insulator Replacement - Front Removal Procedure 1. Remove the front fender liner. 2. Remove the front fender insulator nut by pulling off. 3. Remove the front fender insulator tab from the under fender mounting bracket. 4. Remove the front fender insulator from the inner fender. Installation Procedure Important: The front fender insulator must be kept near the flange of the front fender wheel opening to avoid interference with the front door edge. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Sound Proofing / Insulation > Component Information > Service and Repair > Page 10478 1. Install the front fender insulator to the inner fender. 2. Install the front fender insulator tab to the under fender mounting bracket. 3. Install the nut to the stud by pressing on until fully seated 4. Install the front fender liner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Splash Guard > Component Information > Service and Repair > Splash Shield Replacement - Engine - Left Splash Guard: Service and Repair Splash Shield Replacement - Engine - Left Splash Shield Replacement - Engine - Left Tools Required J 38778Door Trim Pad Clip Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Use J 38778 to remove the push-in retainers holding the engine splash shield to the lower flange of the engine compartment side rail. 3. Remove the engine splash shield from the lower flange of the engine compartment side rail. Installation Procedure 1. Install the engine splash shield to the lower flange of the engine compartment side rail. 2. Align the holes in the engine splash shield to the holes in the outboard side engine compartment side rail. 3. Install the push-in retainers to the engine splash shield. 4. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Splash Guard > Component Information > Service and Repair > Splash Shield Replacement - Engine - Left > Page 10483 Splash Guard: Service and Repair Splash Shield Replacement - Engine - Right Splash Shield Replacement - Engine - Right Tools Required J 38778Door Trim Pad Clip Remover Removal Procedure 1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Use J 38778 to remove the push-in retainers holding the engine splash shield to the lower flange of the engine compartment side rail. 3. For the Impala, remove the front fender liner. Refer to Front Fender Liner Replacement. 4. Remove the engine splash shield from the lower flange of the engine compartment side rail. Installation Procedure 1. Install the engine splash shield to the lower flange of the engine compartment side rail. 2. Align the holes in the engine splash shield to the holes in the outboard side engine compartment side rail. 3. Insert the push-in retainers to the engine splash shield. 4. For the Impala, install the front fender liner. Refer to Front Fender Liner Replacement. 5. Lower the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair Spoiler: Service and Repair Spoiler Replacement - Rear (Impala) Tools Required J 25070 Heat Gun Removal Procedure Notice: Use of harsh chemicals when cleaning can damage exterior lamps. Suggested cleaners are a mild soap and water, or Varnish Makers and Painters (VM&P;) Naptha. VM&P; Naptha is a specific type of naptha and should not be substituted by any other naptha. 1. Open the rear compartment. 2. Remove the nuts from the rear end spoiler studs. 3. Heat the rear end spoiler mounting points from the inside, using J 25070 152 mm (6 in) from surface. Apply heat using a circular motion for about 30 seconds. 4. Remove the rear end spoiler from the rear compartment lid surface using a small wood or plastic flat-bladed tool. Do NOT damage the paint. 5. Remove the rear end spoiler from the rear compartment lid. 6. Clean the rear end spoiler adhesive from the rear compartment lid and/or the rear end spoiler using 3M(TM) Scotch Brite molding adhesive remover disk, 3M(TM) P/N 07501, or equivalent. 7. Clean the body panel using VM&P; Naphtha in order to remove any adhesive. Wipe the surface dry with a clean, lint-free cloth. Installation Procedure Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Spoilers, Flaps, and Air Dams > Spoiler > Component Information > Service and Repair > Page 10488 1. Warm the rear compartment lid with J 25070 from the outside, to a minimum of 21°C (70°F). Important: Do not touch the adhesive backing. 2. Peel the backing from the mounting surfaces of the rear end spoiler. 3. Align the rear end spoiler studs to the holes in the rear compartment lid. 4. Install the rear end spoiler to the rear compartment lid, pressing into place until the adhesive is fully seated. 5. Open the rear compartment. Notice: Refer to Fastener Notice in Service Precautions. Important: Use new nuts/mastic washers in order to avoid a possible water leak. 6. Install the nuts to the rear end spoiler. Tighten the rear end spoiler nuts to 6 N.m (53 lb in). 7. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair Cowl Moulding / Trim: Service and Repair Air Inlet Grille Panel Replacement Tools Required J 38778Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Remove the wiper arms. 3. Disconnect the windshield wiper washer hose from the air inlet grille. 4. Use the J 38778 to remove the push-in retainers from the air inlet grille. 5. Remove the air inlet grille from the vehicle. Installation Procedure 1. Install the air inlet grille to the vehicle. 2. Install the push-in retainers to the air inlet grille. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Unibody > Cowl > Cowl Moulding / Trim > System Information > Service and Repair > Page 10494 3. Install the windshield wiper washer hose to the air inlet grille. 4. Install the wiper arms. 5. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Door Bottom (Impala and Monte Carlo Front) Front Door Weatherstrip: Service and Repair Sealing Strip Replacement - Door Bottom (Impala and Monte Carlo Front) Sealing Strip Replacement - Door Bottom (Impala and Monte Carlo Front) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the front door. 2. Remove the push-in retainers from the front door bottom auxiliary sealing strip using the J 38778. 3. Remove the door bottom auxiliary sealing strip from the front door. Installation Procedure 1. Install the front door bottom auxiliary sealing strip to the front door. 2. Stretch the door bottom auxiliary sealing strip in order to align the push-in retainers to the holes in the front door. 3. Install the push-in retainers to the door bottom auxiliary sealing strip. 4. Close the front door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Weatherstrip > Component Information > Service and Repair > Sealing Strip Replacement - Door Bottom (Impala and Monte Carlo Front) > Page 10500 Front Door Weatherstrip: Service and Repair Weatherstrip Replacement - Front Door Opening (Impala) Weatherstrip Replacement - Front Door Opening (Impala) Removal Procedure 1. Open the front door. 2. Remove the carpet retainers. 3. Remove the windshield garnish molding. 4. Remove the upper center pillar trim panel. 5. Remove the center lower trim panel. 6. Remove the front door opening weatherstrip by pulling it off the pinch-weld flange. Installation Procedure 1. Position the front door opening weatherstrip to the pinch-weld flange. Starting at the center of the rocker panel area and moving in a clockwise direction press the front door opening weatherstrip to the pinch-weld flange until fully seated. Important: The joint butt ends must have no gap and be located in the center of the of the rocker panel area. 2. Install joint butt ends together. 3. Install the carpet retainers. 4. Install the windshield garnish molding. 5. Install the upper center pillar trim panel. 6. Install the center lower trim panel. 7. Close the front door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Channel Retainer Replacement - Front Door (Impala) Removal Procedure 1. Remove the outside rearview mirror. 2. Pull down the front door window channel in order to gain access to the rivets. 3. Loosen the front door frame applique screws. Refer to Door Frame Applique Replacement - Front (Impala) Door Frame Applique Replacement Front (Monte Carlo). 4. Drill out the rivets. 5. Remove the front door window channel retainer from the front door. Installation Procedure 1. Position the front door window channel retainer to the front door. 2. Install the window channel retainer rivets. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the front door frame applique screws. Refer to Door Frame Applique Replacement Front (Impala) Door Frame Applique Replacement Front (Monte Carlo). 4. Install the front door window channel in position. 5. Install the outside mirror. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 10505 Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Front Door Window (Impala) Removal Procedure 1. Remove the front door trim panel. 2. Remove the front door water deflector. 3. Remove the front door outer belt sealing strip. 4. Remove the front door window. 5. Remove the screws from the front door window channel. 6. Remove the front door window channel from the front door frame. 7. Remove the front door window channel from the front door. 8. Remove the screw from the front door rear window channel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 10506 9. Remove the front door rear window channel from the front door slot by pulling down to disengage the retainer clip. 10. Remove the front door rear window channel from the front door through the access hole in the inner front door panel. Installation Procedure 1. Position the front door window channel front channel into the front door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front door window channel screws. Tighten the front door window channel screws to 10 N.m (89 lb in). 3. Install the front door window channel to the front door starting in the top corner working out in both directions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 10507 Firmly seat the front door window channel to the front door. 4. Install the front door rear window channel to the front door through the access hole in the inner front door panel. 5. Install the front door rear window channel to the front door slot by pushing up to engage the retainer clip. 6. Install the screw to the front door rear window channel. Tighten the front door weatherstrip channel screws to 10 N.m (89 lb in). 7. Install the front door window. 8. Inspect the front door window for proper operation. 9. Install the front door outer belt sealing strip. 10. Install the front door water deflector. 11. Install the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 10508 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Outer (Impala) Removal Procedure 1. Remove the outside rearview mirror. 2. Remove the rear screw from the front door outer belt sealing strip. 3. Remove the front door outer belt sealing strip. Installation Procedure 1. Position the front door outer belt sealing strip to the front door pinch-weld flange. 2. Install the front door outer belt sealing strip to the front door pinch-weld flange pressing into place until fully seated. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw to the rear of the front door outer belt sealing strip. Tighten the outer belt sealing strip screw to 2 N.m (18 lb in). 4. Install the outside rearview mirror. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Hood Front Hood Weatherstrip: Service and Repair Seal Replacement - Hood Front Seal Replacement - Hood Front Tools Required J 38778Door Trim Pad Clip Remover Removal Procedure 1. Open the hood. 2. Use J 38778 to remove the push-in retainers from the front air seal. 3. Remove the front air seal from the hood. Installation Procedure 1. Install the front air seal to the hood. 2. Install the push-in retainers to the front air seal into the hood. 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Hood Front > Page 10513 Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Seal Replacement - Hood Rear Removal Procedure 1. Open the hood. 2. Pull the hood rear weatherstrip from the pinch-weld flange. 3. Remove the hood rear weatherstrip from the vehicle. Installation Procedure 1. Install the hood rear weatherstrip to the pinch-weld flange. 2. Press the hood rear weatherstrip onto the pinch-weld flange. 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Hood Front > Page 10514 Hood Weatherstrip: Service and Repair Seal Replacement - Hood Rear Side Seal Replacement - Hood Rear Side Removal Procedure 1. Open the hood. 2. Pull the rear side hood seal from the pinch-weld flange and motor compartment flange. 3. Remove the rear side hood seal from the vehicle. 4. Using 3M(TM) P/N 8984 Adhesive Remover or equivalent, clean any adhesive from the pinch-weld flange and motor compartment flange surface. Installation Procedure 1. Remove the protective backing paper from the adhesive on the rear side hood seal. 2. Install the rear side hood seal to the pinch-weld flange and motor compartment flange. 3. Press the side rear hood seal onto the pinch-weld flange and motor compartment flange until the adhesive is fully adhered. 4. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Hood Weatherstrip > Component Information > Service and Repair > Seal Replacement - Hood Front > Page 10515 Hood Weatherstrip: Service and Repair Seal Replacement - Plenum to Hood Seal Replacement - Plenum to Hood Removal Procedure 1. Open the hood. 2. Remove the right side of the air inlet grille. 3. To remove the seal from the pinch-weld flange, start at the passenger side corner of the seal and pull forward and off of the pinch-weld flange. Installation Procedure 1. Align the seal to the pinch-weld flange. 2. Press to install the seal to the pinch-weld flange, start at the passenger side corner and work toward the center of the car. 3. Install the right side of the air inlet grille. 4. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Opening Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Opening Weatherstrip Replacement - Rear Door Opening Removal Procedure 1. Open the rear door. 2. Remove the trim panels. 3. Remove the weatherstrip from the rear door opening by pulling the weatherstrip off the pinchweld flange. Installation Procedure 1. Position the rear door opening weatherstrip to the pinchweld flange. Starting at the center of the rocker panel area and moving in a clockwise direction, press the weatherstrip to the pinchweld flange until fully seated. Important: The joint butt ends must have no gap and must be located in the center of the of the rocker panel area. 2. Install the joint butt ends together. 3. Install the trim panels. 4. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Opening > Page 10520 Rear Door Weatherstrip: Service and Repair Sealing Strip Replacement - Door Bottom (Impala Rear) Sealing Strip Replacement - Door Bottom (Impala Rear) Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the rear door. 2. Remove the push-in retainers from the rear door bottom auxiliary sealing strip using the J 38778. 3. Remove the door bottom auxiliary sealingstrip from the rear door. Installation Procedure 1. Position the door bottom auxiliary weatherstrip to the rear door. 2. Stretch the door bottom auxiliary weatherstrip in order to align the push-in retainers to the holes in the door. 3. Install the push-in retainers to the door bottom auxiliary weatherstrip. 4. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Opening > Page 10521 Rear Door Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Door Window Weatherstrip Replacement - Rear Door Window (Impala) Removal Procedure 1. Place the rear window in the full down position. 2. Remove the rear door trim panel. 3. Remove the outer belt sealing strip. 4. Remove the rear window channel from the door. Installation Procedure 1. Position the rear window channel to the rear door starting in the corner. Work outward in both directions. 2. Firmly seat the rear window channel to the rear door. 3. Inspect the rear door window for proper operation. 4. Install the outer belt sealing strip. 5. Install the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Weatherstrip > Component Information > Service and Repair > Weatherstrip Replacement - Rear Door Opening > Page 10522 Rear Door Weatherstrip: Service and Repair Rear Side Door Bottom Auxiliary Sealing Strip Replacement Sealing Strip Replacement - Rear Door Bottom Auxiliary Tools Required J 38778 Door Trim Pad Clip Remover Removal Procedure 1. Open the rear door. 2. Remove the push-in retainers from the rear door bottom auxiliary sealing strip using the J 38778. 3. Remove the door bottom auxiliary sealingstrip from the rear door. Installation Procedure 1. Position the door bottom auxiliary weatherstrip to the rear door. 2. Stretch the door bottom auxiliary weatherstrip in order to align the push-in retainers to the holes in the door. 3. Install the push-in retainers to the door bottom auxiliary weatherstrip. 4. Close the rear door. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel Rear Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Channel Retainer Replacement - Rear Door (Impala) Removal Procedure 1. Partially remove the upper portion of the rear door frame appliques. Refer to Door Frame Applique Replacement - Rear (Impala Front) Door Frame Applique Replacement - Rear (Impala Rear). 2. Pull downwards on the rear door window channel to gain access to the rivets. 3. Drill out the rivets. 4. Remove the forward screw to the rear window channel retainer. 5. Remove the rear window channel retainer from the rear door. Installation Procedure 1. Position the rear window weatherstrip retainer. 2. Push downwards on the rear door window channel to gain access to the rivets holes. 3. Install weather strip retainer rivets. 4. Install the rear door frame applique. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 10527 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Rear Door Window (Impala) Removal Procedure 1. Place the rear window in the full down position. 2. Remove the rear door trim panel. 3. Remove the outer belt sealing strip. 4. Remove the rear window channel from the door. Installation Procedure 1. Position the rear window channel to the rear door starting in the corner. Work outward in both directions. 2. Firmly seat the rear window channel to the rear door. 3. Inspect the rear door window for proper operation. 4. Install the outer belt sealing strip. 5. Install the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 10528 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Rear Door Window Belt Outer (Impala) Removal Procedure 1. Position the rear window all the way down. 2. Remove the rear door trim panel to have access to these screws. 3. Remove the rear door outer belt sealing strip screws. 4. Remove the rear window outer belt sealing strip by pulling the sealing strip from the rear door pinch-weld flange. Installation Procedure 1. Position the rear door outer belt sealing strip to the rear door pinch-weld flange. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 10529 2. Install the rear door outer belt sealing strip to the pinch-weld flange, pressing into place until full seated. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the rear door outer belt sealing strip screws. Tighten the rear door outer belt sealing strip screws to 2 N.m (18 lb in). 4. Install Rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Body and Frame > Weatherstrip > Trunk / Liftgate Weatherstrip > Component Information > Service and Repair Trunk / Liftgate Weatherstrip: Service and Repair Weatherstrip Replacement - Rear Compartment Opening (Impala) Removal Procedure 1. Open the rear compartment. 2. Remove the rear compartment weatherstrip from the pinch-weld flange. Installation Procedure 1. Align the metal joint of the weatherstrip to the center of the rear compartment lid striker. Important: In order to minimize bulging conditions, avoid stretching the weatherstrip around the corners. 2. Install the rear compartment weatherstrip onto the pinch-weld flange, starting at the top center of the lid opening and working toward the bottom center. Use a rubber mallet in order to ensure that the weatherstrip is fully engaged to the pinch-weld flange. 3. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations Lower Center Of Instrument Panel (Without RPO Code 9C1/9C3) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10537 Lower Center Of Instrument Panel (Without RPO Code 9C1/9C3) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10538 Cruise Control Release Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10539 Brake Switch (Cruise Control): Adjustments CRUISE RELEASE SWITCH ADJUSTMENT IMPORTANT: The cruise control release switch and the stop lamp switch are adjusted together. Incorrect adjustment of either of these switches may cause premature brake lining wear or the incorrect operation of the cruise control system. 1. Remove the left instrument panel insulator. 2. Press the brake pedal fully. 3. Push the switches into the retainers until the switches are fully seated. 4. Pull the brake pedal fully rearward against the pedal stop until the audible clicks can no longer be heard. 5. Measure the brake pedal travel distances from the centerline of the brake pedal pad. Compare the measurements to the following values. The comparison of the values can verify that the cruise control release switch and the stop lamp switch are correctly adjusted: The cruise control release switch and the stop lamp switch contacts must actuate at 3.5-12.5 mm (0.125-0.500 in) of brake pedal travel. - Nominal actuation of the stop lamp switch contacts occurs about 4.5 mm (0.2 in) beyond the point of cruise control release switch actuation. 6. Install the left instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10540 Brake Switch (Cruise Control): Service and Repair CRUISE RELEASE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the left instrument panel insulator. 2. Disconnect the cruise release switch electrical connector. 3. Remove the cruise release switch from the cruise release switch retainer on the brake pedal bracket. INSTALLATION PROCEDURE 1. Install the cruise release switch to the cruise release switch retainer on the brake pedal bracket. 2. Connect the cruise release switch electrical connector. 3. Adjust the cruise release switch. Refer to Cruise Release Switch Adjustment. 4. Install the left side instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 10544 Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 10545 Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 10546 Cruise Control Module (CCM) Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 10547 Cruise Control Module: Service and Repair CRUISE CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE The cruise control module is mounted to the left strut tower and must be serviced as a complete unit. 1. Remove the cruise control cable from the cruise control module. 2. Disconnect the cruise control module electrical connector. 3. Remove the cruise control module shock tower nuts. 4. Remove the cruise control module. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Module > Component Information > Locations > Page 10548 1. Install the cruise control module on the mounting studs located on the shock tower. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the cruise control module mounting nuts. Tighten Tighten the cruise control module to shock tower nuts to 2 N.m (18 lb in). 3. Connect the cruise control module electrical connector. IMPORTANT: The cruise control cable does not require mechanical adjusting after the replacement. The cruise control module internally adjusts the cable. 4. Install the cruise control cable to the cruise control module. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair Cruise Control Servo Cable: Service and Repair CRUISE CONTROL CABLE REPLACEMENT REMOVAL PROCEDURE 1. Remove the cruise control from the throttle body lever and the accelerator control cable bracket. 2. Remove the cruise control cable from the cruise control cable retainers. 3. Remove the cruise control cable from the cruise control module cable strap. 4. Remove the cruise control cable from the cruise control module by rotating the cruise control cable counterclockwise. 5. Remove the cruise control cable. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Page 10552 1. Position the cruise control cable to the engine. 2. Install the cruise control cable to the module by rotating the cruise control cable clockwise. 3. Install the cruise control cable to the cruise control cable retainers. IMPORTANT: Ensure the module strap is not twisted during installation of the cable. - The cruise control cable does not require mechanical adjusting after the replacement. The cruise control module internally adjusts the cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Service and Repair > Page 10553 4. Install the cruise control cable to the cruise control module cable strap. 5. Install the cruise control cable to the throttle body lever and the accelerator control cable bracket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Locations > Page 10557 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations Cruise Control Module: Locations Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 10562 Left Center Of Engine Compartment Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 10563 Cruise Control Module: Diagrams Cruise Control Module (CCM) Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 10564 Cruise Control Module (CCM) Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 10565 Cruise Control Module: Service and Repair CRUISE CONTROL MODULE REPLACEMENT REMOVAL PROCEDURE The cruise control module is mounted to the left strut tower and must be serviced as a complete unit. 1. Remove the cruise control cable from the cruise control module. 2. Disconnect the cruise control module electrical connector. 3. Remove the cruise control module shock tower nuts. 4. Remove the cruise control module. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Relays and Modules - Cruise Control > Cruise Control Module > Component Information > Locations > Page 10566 1. Install the cruise control module on the mounting studs located on the shock tower. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the cruise control module mounting nuts. Tighten Tighten the cruise control module to shock tower nuts to 2 N.m (18 lb in). 3. Connect the cruise control module electrical connector. IMPORTANT: The cruise control cable does not require mechanical adjusting after the replacement. The cruise control module internally adjusts the cable. 4. Install the cruise control cable to the cruise control module. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations Brake Switch (Cruise Control): Locations Lower Center Of Instrument Panel (Without RPO Code 9C1/9C3) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10571 Lower Center Of Instrument Panel (Without RPO Code 9C1/9C3) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10572 Cruise Control Release Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10573 Brake Switch (Cruise Control): Adjustments CRUISE RELEASE SWITCH ADJUSTMENT IMPORTANT: The cruise control release switch and the stop lamp switch are adjusted together. Incorrect adjustment of either of these switches may cause premature brake lining wear or the incorrect operation of the cruise control system. 1. Remove the left instrument panel insulator. 2. Press the brake pedal fully. 3. Push the switches into the retainers until the switches are fully seated. 4. Pull the brake pedal fully rearward against the pedal stop until the audible clicks can no longer be heard. 5. Measure the brake pedal travel distances from the centerline of the brake pedal pad. Compare the measurements to the following values. The comparison of the values can verify that the cruise control release switch and the stop lamp switch are correctly adjusted: The cruise control release switch and the stop lamp switch contacts must actuate at 3.5-12.5 mm (0.125-0.500 in) of brake pedal travel. - Nominal actuation of the stop lamp switch contacts occurs about 4.5 mm (0.2 in) beyond the point of cruise control release switch actuation. 6. Install the left instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) > Component Information > Locations > Page 10574 Brake Switch (Cruise Control): Service and Repair CRUISE RELEASE SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the left instrument panel insulator. 2. Disconnect the cruise release switch electrical connector. 3. Remove the cruise release switch from the cruise release switch retainer on the brake pedal bracket. INSTALLATION PROCEDURE 1. Install the cruise release switch to the cruise release switch retainer on the brake pedal bracket. 2. Connect the cruise release switch electrical connector. 3. Adjust the cruise release switch. Refer to Cruise Release Switch Adjustment. 4. Install the left side instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations Cruise Control Switch: Locations Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Locations > Page 10578 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10584 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10585 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10586 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10587 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10588 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10589 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10590 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10591 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10592 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10593 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10594 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10595 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10596 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10597 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10598 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10599 Audible Warning Device: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10600 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10601 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10602 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10603 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10604 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10605 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10606 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10607 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10608 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10609 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10610 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10611 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10612 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10613 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10614 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10615 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10616 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10617 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10618 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10619 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10620 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10621 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10622 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10623 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10624 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10625 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10626 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 10627 Audible Warning Device: Electrical Diagrams Audible Warnings Diagram Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 10628 Audible Warning Device: Description and Operation AUDIBLE WARNINGS DESCRIPTION AND OPERATION The audible warnings alert the driver of a system concern or a critical vehicle condition. The radio generates the audible warnings through the left front speaker. The radio receives audible warning requests via the class 2 serial data line. If the radio receives multiple audible warning requests, the warning with the highest priority sounds first. The Multifunction Alarm generates the audible warnings on vehicles with RPO UL5 - Radio Delete Option. The following lists the audible warning priority and the pulse rate: 1. Fast rate chime at 200 pulses per minute 2. Medium rate chime at 150 pulses per minute 3. Slow rate chime at 50 pulses per minute 4. Single chime DOOR AJAR WARNING The radio activates the door ajar audible warning as requested by the body control module (BCM). The BCM sends a class 2 message to the radio indicating the chime frequency of a medium rate and at a continuous duration. The door ajar warning sounds and the door ajar indicator illuminates when the following occurs: 1. The body control module (BCM) determines that the driver's door is open and the signal circuit low. The IPC receives a message via class 2 from the BCM requesting illumination of the door ajar indicator. 2. The vehicle is not in park. The BCM receives a class 2 message from the PCM indicating the gear position. FASTEN SAFETY BELT WARNING The radio activates the fasten safety belt audible warning as requested by the IPC. The IPC sends a class 2 message to the radio indicating the chime frequency of a slow rate and at a duration of 8 seconds. The fasten safety belt warning sounds and the fasten safety belt indicator illuminates when the following occurs: The ignition switch transitions to ON. - The inflatable restraint sensing and diagnostic module (SDM) detects that the driver seat belt is not buckled and the signal is low. The IPC receives a class 2 message from the SDM indicating the driver seat belt status. If the seat belt is buckled when the ignition is turned on, the chime does not sound. If the seat belt is buckled while the chime is sounding, the chime stops. If the seat belt is unbuckled after the initial transition to ON, the chime does not sound. KEY-IN-IGNITION WARNING The radio activates the key-in-ignition audible warning as requested by the IPC. The IPC sends a class 2 message to the radio indicating the chime frequency of a medium rate and at a continuous duration. The key-in-ignition warning sounds when the following occurs: The ignition switch is OFF. - The body control module (BCM) determines that the driver's door is open and the signal circuit is low. The IPC receives a class 2 message from the BCM indicating the door ajar status. - The BCM determines that the key-in-ignition switch is open and the signal circuit is high. The IPC receives a class 2 message from the BCM indicating the key-in-ignition status. LIGHTS ON WARNING The radio activates the lights on warning as requested by the body control module (BCM). The BCM sends a class 2 message to the radio indicating the chime frequency of a fast rate and at a continuous duration. The ignition is OFF. - The BCM determines that the driver door is open and the signal circuit is low. - The BCM determines that the headlamp switch is in the park or head position. PARK BRAKE WARNING The radio activates the park brake audible warning as requested by the IPC. The IPC sends a class 2 message to the radio indicating the chime frequency of a medium rate and at a continuous duration. The park brake warning sounds and the BRAKE indicator illuminates when the following occurs: The ignition is on. - The vehicle is not in park. The IPC receives a class 2 message from the PCM indicating the gear position. - The IPC determines that the park brake is engaged and the signal circuit is low. TURN SIGNAL ON The radio activates the turn signal on audible warning as requested by the body control module (BCM). The BCM sends a class 2 message to the radio indicating the chime frequency of a fast rate and at a duration 2 seconds. ADDITIONAL WARNINGS The following warnings have an associated IPC or message center indicator. ABS The radio activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the radio indicating the chime frequency of a fast rate and a duration of 4 times. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Page 10629 - BRAKE The radio activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the radio indicating the chime frequency of a fast rate and a duration of 4 times. - Charging System The radio activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the radio indicating the chime frequency of a fast rate and a duration of 4 times. - Hot Coolant Temperature The radio activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the radio indicating the chime frequency of a fast rate and at a duration of every three seconds. - Low Coolant Level The radio activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the radio indicating the chime frequency of a fast rate and a duration of 4 times. - LOW OIL PRESSURE The radio activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the radio indicating the chime frequency of a fast rate and at a duration of every three seconds. - Low Fuel The radio activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the radio indicating the chime frequency of a fast rate and a duration of 4 times. - Low Oil Level The radio activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the radio indicating the chime frequency of a fast rate and a duration of 4 times. - SERVICE TRACTION SYSTEM The radio activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the radio indicating the chime frequency of a fast rate and a duration of 4 times. - SERVICE VEHICLE SOON The radio activates the audible warning as requested by the IPC. The IPC sends a class 2 message to the radio indicating the chime frequency of a fast rate and a duration of 4 times. Refer to Indicator/Warning Message Description and Operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Service and Repair > Procedures Audible Warning Device Control Module: Procedures MULTIFUNCTION ALARM MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster trim panel. 2. Remove the screws from the radio delete plate. 3. Remove the radio delete plate from the instrument panel. 4. Disconnect the electrical connector from the multifunction alarm module. 5. Remove the multifunction alarm module from the instrument panel by lifting up and out. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Service and Repair > Procedures > Page 10634 1. Install the multifunction alarm module to the instrument panel by pressing in place until fully seated. 2. Connect the electrical connector to the multifunction alarm module. 3. Install the radio delete plate to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the radio delete plate. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the instrument cluster trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Service and Repair > Procedures > Page 10635 Audible Warning Device Control Module: Removal and Replacement Multifunction Alarm Module Replacement Removal Procedure 1. Remove the instrument cluster trim panel. 2. Remove the screws from the radio delete plate. 3. Remove the radio delete plate from the instrument panel. 4. Disconnect the electrical connector from the multifunction alarm module. 5. Remove the multifunction alarm module from the instrument panel by lifting up and out. Installation Procedure 1. Install the multifunction alarm module to the instrument panel by pressing in place until fully seated. 2. Connect the electrical connector to the multifunction alarm module. 3. Install the radio delete plate to the instrument panel. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the radio delete plate. Tighten the screws to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device Control Module > Component Information > Service and Repair > Procedures > Page 10636 5. Install the instrument cluster trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions Brake Warning Indicator: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10641 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10642 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10643 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10644 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10645 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10646 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10647 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10648 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10649 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10650 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10651 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10652 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10653 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10654 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10655 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10656 Brake Warning Indicator: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10657 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10658 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10659 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10660 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10661 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10662 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10663 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10664 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10665 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10666 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10667 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10668 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10669 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10670 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10671 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10672 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10673 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10674 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10675 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10676 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10677 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10678 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10679 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10680 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10681 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10682 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10683 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 10684 Brake Warning System Schematics Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10689 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10690 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10691 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10692 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10693 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10694 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10695 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10696 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10697 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10698 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10699 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10700 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10701 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10702 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10703 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10704 Cigarette Lighter: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10705 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10706 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10707 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10708 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10709 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10710 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10711 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10712 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10713 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10714 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10715 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10716 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10717 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10718 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10719 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10720 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10721 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10722 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10723 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10724 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10725 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10726 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10727 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10728 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10729 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10730 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10731 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10732 Cigar Lighter Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 10733 Cigarette Lighter: Electrical Diagrams Cigar Lighter/Auxiliary Outlets Diagram Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Service and Repair > Cigar Lighter Housing Replacement - Instrument Panel (I/P) Cigarette Lighter: Service and Repair Cigar Lighter Housing Replacement - Instrument Panel (I/P) CIGAR LIGHTER HOUSING REPLACEMENT - INSTRUMENT PANEL (I/P) TOOLS REQUIRED J 42059 Cigar Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the cigar lighter fuse. 2. Remove the cigar lighter housing by placing one side of the "T" portion of J 42059 into the tab window. Angle the other side into the opposite tab window. Pull the power accessory port housing straight out. 3. If the standard method fails to remove the housing, use the following alternate method: 3.1. Insert a small grinding tool with a cutoff wheel into the housing. 3.2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 3.3. Use the J 42059 as directed above to remove the housing. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Service and Repair > Cigar Lighter Housing Replacement - Instrument Panel (I/P) > Page 10736 4. Remove the tool from the cigar lighter housing. 5. Disconnect the electrical connector from the cigar lighter. 6. Use your index finger in order to pull out the cigar lighter housing retainer. INSTALLATION PROCEDURE 1. Align the housing retainer to the slot in the cigar lighter hole. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Service and Repair > Cigar Lighter Housing Replacement - Instrument Panel (I/P) > Page 10737 2. Install the housing retainer. Press into place until the retainer is fully seated. 3. Connect the electrical connector to the cigar lighter housing. 4. Align the cigar lighter housing tabs to the retainer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Service and Repair > Cigar Lighter Housing Replacement - Instrument Panel (I/P) > Page 10738 5. Install the cigar lighter housing. Press the housing into place until fully seated. 6. Install the cigar lighter fuse. 7. Inspect the cigar lighter for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Service and Repair > Cigar Lighter Housing Replacement - Instrument Panel (I/P) > Page 10739 Cigarette Lighter: Service and Repair Cigar Lighter Housing Replacement - Floor Console CIGAR LIGHTER HOUSING REPLACEMENT - FLOOR CONSOLE TOOLS REQUIRED J 42059 Cigar Lighter Socket Remover REMOVAL PROCEDURE 1. Remove the cigar lighter fuse. 2. Remove the cigar lighter element. 3. Remove the cigar lighter housing by placing one side of the T portion of J 42059 into the tab window. Angle the other side of the tool into the opposite tab window. Pull the lighter housing straight out. 4. If the standard method fails to remove the housing, use the following alternate method: 4.1. Insert a small grinding tool with a cutoff wheel into the housing. 4.2. Remove the plastic latches in the 3 mm (0.11 in) square windows. 4.3. Use J 42059 as directed above to remove the housing. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Service and Repair > Cigar Lighter Housing Replacement - Instrument Panel (I/P) > Page 10740 5. Remove J 42059 from the lighter housing. 6. Disconnect the electrical connector from the cigar lighter housing. 7. Using your index finger, pull out the housing retainer. INSTALLATION PROCEDURE 1. Position the cigar lighter housing retainer to the slot into the cigar lighter hole. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Service and Repair > Cigar Lighter Housing Replacement - Instrument Panel (I/P) > Page 10741 2. Install the housing retainer. Press the retainer into place until fully seated. 3. Connect the electrical connector to the cigar lighter housing. 4. Align the housing tabs to the cigar lighter retainer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Service and Repair > Cigar Lighter Housing Replacement - Instrument Panel (I/P) > Page 10742 5. Press the cigar lighter housing into place until fully seated. 6. Install the cigar lighter element. 7. Install the cigar lighter fuse. 8. Inspect the I/P lighter for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations Above The Driver Information Center (DIC) (CF5) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information > Locations > Page 10746 Compass: Service and Repair ELECTRONIC COMPASS CALIBRATION The electronic compass is capable of distinguishing 8 primary directions: - North (N) - Northeast (NE) - East (E) - Southeast (SE) - South (S) - Southwest (SW) - West (W) - Northwest (NW) The compass calibration procedures establish a base direction from which the compass can work. Once the compass has been properly calibrated, the digital display indicates the direction of vehicle travel. CALIBRATION PROCEDURE The compass is self-calibrating, eliminating the need to manually set the compass. Occasionally, the calibration process on a new vehicle may not be complete, causing the CAL symbol to illuminate. In order to correct this problem, drive the vehicle less than 8 km/h (5 mph) through 3 complete 360 degree turns. The CAL symbol will then turn OFF and the compass will function normally. If the compass appears erratic and the CAL symbol does not appear, you must manually put the compass into the calibration mode. 1. Turn ON the ignition. 2. Press the MODE button until the compass/temperature mode appears. 3. Press and hold the RESET button on the overhead console for approximately 10 seconds, or until the display reads CAL. 4. Release the RESET button and drive the vehicle less than 8 km/h (5 mph) through 3 complete 360 degree turns. The CAL symbol will turn off when the compass is calibrated, and the compass will function normally. VARIANCE Variance is defined as the difference between magnetic north and geographic north. In some areas of the country, this difference is great enough to cause false compass readings. Set the variance for a particular location as follows: 1. Determine the vehicle's location on the zone map. Note the zone number. 2. Turn ON the ignition. 3. Press the MODE button until the compass/temperature mode appears. 4. Press and hold the RESET button on the overhead console for approximately 5 seconds. The last entered variance zone appears on the display. 5. Press the MODE button until the correct zone number appears on the display. 6. Press the RESET button in order to set the new variance zone and resume normal operation. The display will illuminate all segments briefly in order to acknowledge the change in the zone number. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Disabling And Enabling Zones Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10752 The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10753 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the radiator upper air baffle and deflector. 7. Remove the orange connector position assurance (CPA) (2) from the yellow sensor harness connector (3). 8. Disconnect the sensor harness connector from the sensor (1). Zone 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10754 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the side impact sensor (SIS)-LF from the center pillar. 7. Remove the connector position assurance (CPA) from the SIS-LF connector (2). 8. Disconnect the SIS-LF connector (2) from the SIS-LF (1). Zone 3 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10755 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the LH insulator panel. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Disconnect the steering wheel module coil connector. Zone 5 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10756 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the RH IP access hole cover. 7. Remove the connector position assurance (CPA) from the inflatable restraint IP module connector located to the right of the steering column. 8. Disconnect the IP module connector. Zone 7 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10757 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the fuse block access cover. 5. Remove the SIR Fuse. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the side impact module - LF connector (1) located under the driver seat. 7. Disconnect the side impact module - LF connector (1). Zone 9 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10758 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the I/P fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the LH insulator panel. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Disconnect the steering wheel module coil connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10759 9. Remove the RH I/P access hole cover. 10. Remove the CPA from the inflatable restraint I/P module connector, located at the RH side of the I/P. 11. Disconnect the I/P module connector. 12. Remove the CPA from the inflatable restraint side impact module - LF connector (1), located under the driver seat. 13. Disconnect the side impact module - LF connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10760 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition. 2. Connect the sensor harness connector (3) to the sensor (1). 3. Install the orange CPA (2) into the yellow sensor harness connector (3). 4. Install the radiator upper air baffle and deflector. 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash seven times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10761 1. Connect the SIS-LF connector (2) to the SIS-LF (1). 2. Install the CPA to the SIS-LF connector(2). 3. Install the side impact sensor (SIS)-LF into the center pillar. 4. Install the SIR Fuse. 5. Install the fuse block access cover. 6. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. 2. Connect the steering wheel module coil connector. 3. Install the CPA from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 4. Install the LH insulator panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10762 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash seven times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the IP module connector. 3. Install the CPA into the IP module connector located to the right of the steering column. 4. Install the LH insulator panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10763 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Connect the inflatable restraint side impact module - LF connector (1) located under the driver seat. 2. Install the CPA to the side impact module - LF connector (1). 3. Remove the SIR Fuse. 4. Install the fuse block access cover. 5. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 5.1. The AIR BAG indicator will flash seven times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10764 1. Remove the key from the ignition. Connect the inflatable restraint side impact module - LF connector (1), located under the driver seat. 2. Install the CPA to the side impact module - LF connector. 3. Connect the inflatable restraint I/P module connector, located at the RH side of the I/P. 4. Install the CPA to the I/P module connector. 5. Install the RH I/P access hole cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10765 6. Connect the steering wheel module coil connector. 7. Install the CPA from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Install the LH insulator panel. 9. Install the SIR Fuse. 10. Install the LH I/P access hole cover. 11. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 11.1. The AIR BAG indicator will flash seven times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation DOOR AJAR INDICATOR DESCRIPTION AND OPERATION DOOR AJAR INDICATOR The IPC illuminates the DOOR AJAR indicator in the message center when the body control module (BCM) detects that the driver or passenger door is open. The IPC receives a class 2 message from the BCM requesting illumination. If the vehicle is in a forward or reverse gear position, the BCM sends a class 2 message to the radio in order to activate an audible warning. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Instruments - DIC Perceived Fuel Economy Settings Driver/Vehicle Information Display: Technical Service Bulletins Instruments - DIC Perceived Fuel Economy Settings Bulletin No.: 03-00-89-021 Date: July 30, 2003 INFORMATION Subject: New Vehicle Pre-Delivery Inspection - Perceived Fuel Economy and Driver Information Center (DIC) Settings Models: 2003-2004 Passenger Cars and Trucks 2003-2004 HUMMER H2 with Driver Information Center (DIC) The customer's initial perception of vehicle fuel economy, based upon the information displayed on the Driver Information Center (DIC), may contribute to poor ratings for fuel economy in various automotive surveys. The way the vehicle is handled during the build and shipping process may leave inaccurate values in the history of the DIC. During the pre-delivery inspection, the dealership must reset the "average fuel economy" setting. Reset the average fuel economy setting according to the information in the appropriate Owner's Manual. Once reset, the average fuel economy will then be calculated starting from that point. The data used to determine fuel range is an average of recent driving conditions. This setting cannot be reset. However, as the customer's driving conditions change, the data will be gradually updated to reflect more accurate readings. If a customer inquires about fuel economy, and the fuel consumption information is not on the price sticker, do not exaggerate the vehicle's capabilities. In either case, stress that fuel economy performance is highly dependent upon driving habits and vehicle usage. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 10773 Driver/Vehicle Information Display: Diagrams Driver Information Center (DIC), C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 10774 Driver Information Center (DIC), C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 10775 Driver Information Center (DIC), C2 (With RPO Code CF5) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 10776 Driver/Vehicle Information Display: Description and Operation DRIVER INFORMATION CENTER (DIC) DESCRIPTION AND OPERATION When the driver information center (DIC) powers up it will display all segments on for 2 seconds. Then the DIC will return to display status it had before no power condition. In the absence of vehicle communications, a double dash (--) displays in the digits section. An error of the speed sensor or fuel sender will cause -E- to be displayed. There are 2 buttons on the DIC. - RESET button - MODE button RESET BUTTON You can reset the AVG ECON, FUEL USED or AVG SPEED trip computer modes by pressing and holding the RESET button for three seconds while you are in the mode you wish to reset. A chime will sound to confirm that your requested change has been made and all the segments of the display will briefly light up. To change the display to a metric or English reading, press the RESET and MODE buttons at the same time. Hold them down for three seconds, and the display will change. A chime will be heard to confirm the new selection. The DIC will send a class 2 message to the IPC to change the units displayed in the odometer. MODE Button The display format for each mode is indicated in the shown table. Pressing the MODE button changes the modes of operation for the DIC. There are seven display modes available. Off - No driver information is displayed in this mode of operation. - Compass/Temperature - Average Fuel Economy (AFE) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Technical Service Bulletins > Page 10777 - Instantaneous Fuel Economy (IFE) - Trip Range - Fuel Used - Average Speed COMPASS/TEMPERATURE MODE This mode displays an 8 point compass heading on the left hand side of the DIC. The compass will display the current vehicle direction relative to one of 8 compass headings using N, NE, E, SE, S, SW, W, and NW for the readout. The ambient temperature displays on the right hand side of the DIC. If the ambient temperature is below 3°C (37°F), the temperature reading will toggle between displaying the outside temperature and the word ICE for two minutes. If the temperature is less than minus 40°F for more than 2 seconds, OC will display. If the temperature is above 140°F for more than 2 seconds, SC will be displayed. If OC or SC is displayed DTC's will be set. For compass calibration and compass magnetic variation adjustment refer to Electronic Compass Calibration. AVERAGE FUEL ECONOMY (AVG) AFE is calculated as the ratio between the following values: AFE=Distance/Fuel - Distance=The accumulated distance since the last AFE reset - Fuel=The accumulated fuel consumption since the last AFE reset You can reset the AFE mode by pressing the RESET button for more than 3 seconds while in this mode. The value of this mode is retained during ignition OFF. INSTANTANEOUS FUEL ECONOMY (INST) Instantaneous fuel economy is calculated as the ratio between the following values: IFE=Distance/Fuel - Distance=The accumulated distance since last update - Fuel=The accumulated fuel delivered since last update You cannot reset the IFE mode. The value of this mode is retained during ignition OFF. TRIP RANGE (RANGE) Trip Range is calculated between the following values: Trip Range=AFE x Fuel Remaining - Fuel Remaining=Fuel sender value of available fuel You cannot reset the Trip Range mode. The value of this mode is retained during ignition OFF. FUEL USED The DIC calculates and displays the total amount of fuel used since the last reset operation. You can reset the Fuel Used mode by pressing the RESET button for more than 3 seconds while in this mode. The value of this mode is retained during ignition OFF. AVERAGE SPEED (AVG SPEED) Average speed is calculated as the ratio between the following values: Average Speed=Distance/Ignition On - Distance=Accumulated distance since last reset - Ignition On=Accumulated ignition on time since last reset Ignition on time is measured from the time that the ignition is turned ON, to the time when the ignition is turned OFF. You can reset the Average Speed mode by pressing the RESET button for more than 3 seconds while in this mode. The value of this mode is retained during ignition OFF. DIMMING CONTROL Display dimming for the DIC follows the radio dimming characteristics. Upon activation of the parklamps, the display steps from maximum brightness to dim. While in the dim mode, further dimming is controlled by the PWM Dimming Signal of the IP dimming control. The display goes blank upon lowest dimming request of the dimming control. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures Driver/Vehicle Information Display: Procedures Driver Info Center Replacement (With RPO Code UG1, Except CF5) DRIVER INFORMATION CENTER REPLACEMENT (UG1, EXC CF5) REMOVAL PROCEDURE IMPORTANT: The driver information center is serviced as part of the complete roof console. 1. Remove the roof console screw. 2. Use a small, flat-bladed tool in order to release the 2 retainers. These retainers are located on each side of the assembly in front of the switches. Press the retainers outward to release the roof console. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 10780 3. Lower the roof console from the headliner. 4. Disconnect the electrical connectors from the roof console. 5. Remove the roof console backing plate. 6. Remove the roof console. INSTALLATION PROCEDURE IMPORTANT: When installing the roof console, apply foam tape to the wiring harness. Secure the wiring harness in the proper position to the headliner. 1. Apply foam tape to the wiring harness at the headliner. 2. Install the roof console backing plate. 3. Connect the electrical connectors to the roof console. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 10781 4. Position the roof console to the roof console backing plate in the headliner. 5. Install the roof console by pressing the console into place until the retainers are completely engaged. NOTE: Refer to Fastener Notice in Service Precautions. 6. Install the roof console screw. Tighten Tighten the screw to 2 N.m (18 lb in). Driver Information Center Replacement (With RPO Code CF5) DRIVER INFORMATION CENTER REPLACEMENT (CF5) REMOVAL PROCEDURE IMPORTANT: The driver information center is serviced as part of the complete roof console. 1. Remove the roof console screw. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 10782 2. Use a small, flat-bladed tool in order to release the 2 retainers. These retainers are located on each side of the assembly in front of the switches. Press the retainers outward to release the roof console. 3. Lower the roof console from the headliner. 4. Disconnect the electrical connectors from the roof console. 5. Remove the roof console. 6. Remove the sunshade anchors. 7. Lower the headliner at the sunroof opening. Reach between the headliner and the roof to remove the foam tape from the wiring harness on the roof console backing plate. 8. Adjust the wiring harness for access. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 10783 9. Slide the roof console backing plate (2) forward and remove the backing plate from the front of the headliner. INSTALLATION PROCEDURE 1. Position the roof console backing plate (2) to the headliner opening. 2. Secure the wiring harness in the original position to the roof console backing plate. 3. Connect the electrical connectors to the roof console. 4. Install the headliner. 5. Install the sunshade anchors. 6. Position the roof console to the roof console backing plate in the headliner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 10784 7. Install the roof console by pressing the console into place until the retainers are completely engaged. NOTE: Refer to Fastener Notice in Service Precautions. 8. Install the to the roof console screw. Tighten Tighten the screw to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 10785 Driver/Vehicle Information Display: Removal and Replacement Driver Information Center Replacement (CF5) Driver Information Center Replacement (CF5) Removal Procedure Important: The driver information center is serviced as part of the complete roof console. 1. Remove the roof console screw. 2. Use a small, flat-bladed tool in order to release the 2 retainers. These retainers are located on each side of the assembly in front of the switches. Press the retainers outward to release the roof console. 3. Lower the roof console from the headliner. 4. Disconnect the electrical connectors from the roof console. 5. Remove the roof console. 6. Remove the sunshade anchors. 7. Lower the headliner at the sunroof opening. Reach between the headliner and the roof to remove the foam tape from the wiring harness on the roof console backing plate. Refer to Headliner Replacement (Impala) Headliner Replacement (Monte Carlo) in Interior Trim. 8. Adjust the wiring harness for access. 9. Slide the roof console backing plate (2) forward and remove the backing plate from the front of the headliner. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 10786 Installation Procedure 1. Position the roof console backing plate (2) to the headliner opening. 2. Secure the wiring harness in the original position to the roof console backing plate. 3. Connect the electrical connectors to the roof console. 4. Install the headliner. 5. Install the sunshade anchors. 6. Position the roof console to the roof console backing plate in the headliner. 7. Install the roof console by pressing the console into place until the retainers are completely engaged. Notice: Refer to Fastener Notice in Service Precautions. 8. Install the to the roof console screw. Tighten the screw to 2 N.m (18 lb in). Driver Information Center Replacement (UG1, EXC CF5) Driver Information Center Replacement (UG1, EXC CF5) Removal Procedure Important: The driver information center is serviced as part of the complete roof console. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 10787 1. Remove the roof console screw. 2. Use a small, flat-bladed tool in order to release the 2 retainers. These retainers are located on each side of the assembly in front of the switches. Press the retainers outward to release the roof console. 3. Lower the roof console from the headliner. 4. Disconnect the electrical connectors from the roof console. 5. Remove the roof console backing plate. 6. Remove the roof console. Installation Procedure Important: When installing the roof console, apply foam tape to the wiring harness. Secure the wiring harness in the proper position to the headliner. 1. Apply foam tape to the wiring harness at the headliner. 2. Install the roof console backing plate. 3. Connect the electrical connectors to the roof console. 4. Position the roof console to the roof console backing plate in the headliner. 5. Install the roof console by pressing the console into place until the retainers are completely engaged. Notice: Refer to Fastener Notice in Service Precautions. 6. Install the roof console screw. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display > Component Information > Service and Repair > Procedures > Page 10788 Tighten the screw to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Description and Operation Fuel Gauge: Description and Operation FUEL GAGE The IPC displays the fuel level as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the fuel level percent. The fuel gage defaults to empty if: The PCM detects a malfunction in the fuel level sensor circuit. - The IPC detects a loss of class 2 communications with the PCM. When the fuel level is less than a pre-determined value, the low fuel indicator illuminates. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications Fuel Gauge Sender: Specifications FUEL LEVEL SPECIFICATIONS The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 10795 Fuel Gauge Sender: Locations Fuel Pump And Sender Assembly Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 10796 Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 10797 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Specifications > Page 10798 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Remove the fuel sender assembly. 2. Disconnect the fuel level sensor electrical connector. 3. Remove the fuel level sensor (5) from the fuel sender assembly. INSTALLATION PROCEDURE 1. Install the fuel level sensor (5) to the fuel sender assembly. 2. Connect the fuel level sensor electrical connector. 3. Install the fuel sender assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling Air Bag(s) Arming and Disarming: Service and Repair Disabling and Enabling IMPORTANT: Refer to SIR Service Precautions before disabling the SIR system. SIR Disabling And Enabling Zones Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10804 The SIR system has been divided into Disabling and Enabling Zones. When performing service on or near SIR components or SIR wiring, it may be necessary to disable the SIR components in that zone. It may be necessary to disable more than one zone depending on the location of other SIR components and the area being serviced, refer to SIR Zone Identification Views. Refer to the illustration below, to identify the specific zone or zones in which service will be performed. After identifying the zone or zones, proceed to the disabling and enabling procedures for that particular zone or zones. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10805 Air Bag(s) Arming and Disarming: Service and Repair Disabling Zone 1 IMPORTANT: Refer to SIR Service Precautions. 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the radiator upper air baffle and deflector. 7. Remove the orange connector position assurance (CPA) (2) from the yellow sensor harness connector (3). 8. Disconnect the sensor harness connector from the sensor (1). Zone 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10806 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. IMPORTANT: Refer to SIR Service Precautions. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the side impact sensor (SIS)-LF from the center pillar. 7. Remove the connector position assurance (CPA) from the SIS-LF connector (2). 8. Disconnect the SIS-LF connector (2) from the SIS-LF (1). Zone 3 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10807 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the LH insulator panel. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Disconnect the steering wheel module coil connector. Zone 5 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10808 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the IP fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the RH IP access hole cover. 7. Remove the connector position assurance (CPA) from the inflatable restraint IP module connector located to the right of the steering column. 8. Disconnect the IP module connector. Zone 7 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10809 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the fuse block access cover. 5. Remove the SIR Fuse. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 6. Remove the connector position assurance (CPA) from the side impact module - LF connector (1) located under the driver seat. 7. Disconnect the side impact module - LF connector (1). Zone 9 IMPORTANT: Refer to SIR Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10810 1. Turn the steering wheel so that the vehicle's wheels are pointing straight ahead. 2. Turn OFF the ignition. 3. Remove the key from the ignition switch. 4. Remove the I/P fuse block cover. IMPORTANT: With the SIR Fuse removed and the ignition ON, the AIR BAG indicator illuminates. This is normal operation, and does not indicate an SIR system malfunction. 5. Remove the SIR Fuse. 6. Remove the LH insulator panel. 7. Remove the connector position assurance (CPA) from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Disconnect the steering wheel module coil connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10811 9. Remove the RH I/P access hole cover. 10. Remove the CPA from the inflatable restraint I/P module connector, located at the RH side of the I/P. 11. Disconnect the I/P module connector. 12. Remove the CPA from the inflatable restraint side impact module - LF connector (1), located under the driver seat. 13. Disconnect the side impact module - LF connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10812 Air Bag(s) Arming and Disarming: Service and Repair Enabling Zone 1 1. Remove the key from the ignition. 2. Connect the sensor harness connector (3) to the sensor (1). 3. Install the orange CPA (2) into the yellow sensor harness connector (3). 4. Install the radiator upper air baffle and deflector. 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash seven times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10813 1. Connect the SIS-LF connector (2) to the SIS-LF (1). 2. Install the CPA to the SIS-LF connector(2). 3. Install the side impact sensor (SIS)-LF into the center pillar. 4. Install the SIR Fuse. 5. Install the fuse block access cover. 6. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 6.1. The AIR BAG indicator will flash 7 times. 6.2. The AIR BAG indicator will then turn OFF. 7. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 3 1. Remove the key from the ignition. 2. Connect the steering wheel module coil connector. 3. Install the CPA from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 4. Install the LH insulator panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10814 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash seven times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 5 1. Remove the key from the ignition. 2. Connect the IP module connector. 3. Install the CPA into the IP module connector located to the right of the steering column. 4. Install the LH insulator panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10815 5. Install the SIR Fuse. 6. Install the IP fuse block cover. 7. Staying well away from all inflator modules, turn ON the ignition. 7.1. The AIR BAG indicator will flash 7 times. 7.2. The AIR BAG indicator will then turn OFF. 8. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 7 1. Connect the inflatable restraint side impact module - LF connector (1) located under the driver seat. 2. Install the CPA to the side impact module - LF connector (1). 3. Remove the SIR Fuse. 4. Install the fuse block access cover. 5. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 5.1. The AIR BAG indicator will flash seven times. 5.2. The AIR BAG indicator will then turn OFF. 6. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Zone 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10816 1. Remove the key from the ignition. Connect the inflatable restraint side impact module - LF connector (1), located under the driver seat. 2. Install the CPA to the side impact module - LF connector. 3. Connect the inflatable restraint I/P module connector, located at the RH side of the I/P. 4. Install the CPA to the I/P module connector. 5. Install the RH I/P access hole cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s) Arming and Disarming > System Information > Service and Repair > Disabling and Enabling > Page 10817 6. Connect the steering wheel module coil connector. 7. Install the CPA from the inflatable restraint steering wheel module coil connector located at the base of the steering column. 8. Install the LH insulator panel. 9. Install the SIR Fuse. 10. Install the LH I/P access hole cover. 11. Staying well away from all inflator modules and pretensioners, turn ON the ignition. 11.1. The AIR BAG indicator will flash seven times. 11.2. The AIR BAG indicator will then turn OFF. 12. Perform Diagnostic System Check - Restraint Systems if the AIR BAG indicator does not operate as described. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Indicator - A/T > Component Information > Service and Repair Maintenance Indicator - A/T: Service and Repair This vehicle does not use a Trans Fluid Life index, and has no monitor to reset. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation Malfunction Indicator Lamp: Description and Operation MALFUNCTION INDICATOR LAMP (MIL) OPERATION The malfunction indicator lamp (MIL) is located in the instrument panel cluster. The MIL will display as either SERVICE ENGINE SOON or one of the following symbols when commanded ON: The MIL indicates that an emissions related fault has occurred and vehicle service is required. The following is a list of the modes of operation for the MIL: - The MIL illuminates when the ignition is turned ON, with the engine OFF. This is a bulb test to ensure the MIL is able to illuminate. - The MIL turns OFF after the engine is started if a diagnostic fault is not present. - The MIL remains illuminated after the engine is started if the control module detects a fault. A diagnostic trouble code (DTC) is stored any time the control module illuminates the MIL due to an emissions related fault. The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate. - The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter. - When the MIL is illuminated and the engine stalls, the MIL will remain illuminated as long as the ignition is ON. - When the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition is cycled OFF and then ON. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Description and Operation > Page 10824 Malfunction Indicator Lamp: Service and Repair SERVICE VEHICLE SOON INDICATOR The "SERVICE VEHICLE SOON" light will come on if there are certain non-emission related vehicle problems. These problems may not be obvious and may affect vehicle performance or durability. The light will come on briefly when the ignition is turned on to show that it is working properly. This light does NOT come on at certain mileage intervals. There is probably a PCM or a BCM Code set that will aid you in diagnosis. RESET PROCEDURE The only way to get the light to go off is to clear the PCM or BCM code(s). This light can NOT be reset or shut off any other way. PCM/BCM codes should be read & repaired before clearing them. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide Odometer: Technical Service Bulletins Instruments - IPC Odometer Programming Reference Guide INFORMATION Bulletin No.: 07-08-49-020D Date: December 06, 2010 Subject: IPC Odometer Programming Method Quick Reference Guide Models: 2003-2011 GM Passenger Cars and Trucks (Including Saturn) 2003-2010 HUMMER H2, H3 2005-2009 Saab 9-7X Attention: This bulletin applies to vehicles sold in the U.S. and Canada Only. Supercede: This bulletin is being revised to add information for the 2011 model year and add new 2011 vehicles. Please discard Corporate Bulletin Number 07-08-49-020C (Section 08 - Body and Accessories). The purpose of this bulletin is to provide a reference guide to help identify which season odometer programming method to use after replacing the instrument panel cluster (IPC). The three season odometer programming methods in use today are listed below. In addition, this reference guide lists the component where the season odometer value is stored. The season odometer value may be stored in the IPC, the driver information center (DIC) or the integrated body control module (IBCM), also commonly called a body control module (BCM). Season Odometer Programming Methods in Use Today 1. IPC reprogramming and setup using the service programming system (SPS). 2. Odometer setup at the electronic service center (ESC) when using an exchange IPC/DIC. 3. Tech 2(R) - The Tech 2 is used to set up a replacement BCM, which includes loading the odometer value that is displayed and stored in the IPC. A replacement IPC will display the previously stored vehicle odometer value, communicated from the BCM, after cycling the ignition or driving the vehicle. *The odometer programming is integrated as part of the BCM programming procedure. It is not a stand-alone event. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 10829 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 10830 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Instruments - IPC Odometer Programming Reference Guide > Page 10831 Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Page 10832 Odometer: Description and Operation ODOMETER The IPC contains a season odometer and a trip odometer. Momentarily press the trip/reset switch on the IPC in order to toggle between the season odometer and the trip odometer. Press the trip/reset switch for greater than 2 seconds, while the trip odometer is displayed, in order to reset the trip odometer. The IPC displays the vehicle mileage and trip mileage as determined by the IPC. The IPC calculates the mileage based on the class 2 vehicle speed message from the PCM. The IPC calculates mileage based on the class 2 wheel speed message from the EBCM if a loss of communication or malfunction occurs with the PCM. The odometer will display 'error' if an internal IPC memory failure is detected. The odometer displays either miles or kilometers as requested by the activation of the English/metric button on the driver information center (DIC). The associated indicator km illuminates in metric mode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Instruments - Oil Life Monitoring System Oil Change Reminder Lamp: Technical Service Bulletins Instruments - Oil Life Monitoring System Bulletin No.: 04-06-04-045 Date: June 22, 2004 INFORMATION Subject: Oil Life Monitoring System - PCM Reset Models: 2004 All GM Passenger Cars and Trucks Important: The Oil Life Monitoring System can be found on many General Motor's vehicles prior to 2004. Refer to SI and/or the Owner's Manual for detailed information. The purpose of this bulletin is to help technicians identify which vehicles are equipped with the oil life monitoring system. Although many General Motors vehicles prior to 2004 have been equipped with the oil life monitoring system, the 2004 model year vehicles were used as a starting point to validate the system/scan tool functionality. Customers have come to depend on the Oil Life Monitoring System found on most General Motor's vehicles to inform them when it's time for an oil change. If for any reason the PCM is replaced, it is important to access the "Percent of Oil Life Remaining" from the vehicle's current PCM PRIOR to removing the PCM. This value must be programmed into the new PCM (after it is installed in the vehicle) by using the scan tool. Note: Failure to reprogram the value to the new PCM will result in missed maintenance, which may cause damage to the engine. Important: If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to changed at 5,000 km (3,000 mi) from the last engine oil change. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Page 10837 Oil Change Reminder Lamp: Description and Operation WHEN TO CHANGE ENGINE OIL Your vehicle has a computer system that lets you know when to change the engine oil and filter. This is based on engine revolutions and engine temperature and on a maximum mileage of 10,000 miles (16 000 km). Under severe conditions the indicator may come on before 10,000 miles (16 000 km). Never drive your vehicle more then 10,000 miles (16 000 km) or 12 months without an oil and filter change. Based on driving conditions, the mileage at which an oil change will be indicated can vary considerably. For the oil life system to work properly, you must reset the system every time the oil is changed. When the system has calculated that oil life has been diminished, it will indicate that an oil change is necessary. A "CHANGE ENGINE OIL" message or a "CHANGE OIL" indicator will come on. Change your oil as soon as possible within the next two times you stop for fuel. It is possible that, if you are driving under the best conditions, the oil life system may not indicate that an oil change is necessary for over a year. However, your engine oil and filter must be changed at least once a year and at this time the system must be reset. It is also important to check your oil regularly and keep it at the proper level. The engine oil life monitor will not detect dust in the oil. If the vehicle is driven in a dusty area, be sure to change the oil every 5,000 km (3,000 miles) or sooner if the "CHANGE ENGINE OIL" light is displayed. If the system is ever reset accidentally, you must change your oil at 10,000 miles (16 000 km) since your last oil change. Remember to reset the oil life system whenever the oil is changed. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > Page 10838 Oil Change Reminder Lamp: Service and Repair GM OIL LIFE SYSTEM - RESETTING USING THE RADIO 1. Turn the ignition to "ACC" OR "ON", with the radio off. 2. Press and hold the "TUNE DISP" button on the radio for at least five seconds until "SETTINGS" is displayed. 3. Press the "SEEK PTYPE" or the "SEEK PSCAN" up or down arrow to scroll through the main menu. 4. Scroll until "OIL LIFE" appears on the display. 5. Press the "1 PREV" or "2 NEXT" button to enter the submenu. "RESET" will be displayed. 6. Press the "TUNE DISP" button to reset. A chime will be heard to verify the new setting and "DONE" will be displayed for one second. 7. Once the message has been reset, scroll until "EXIT" appears on the display. 8. Press the "TUNE DISP" button to exit programming. A chime will be heard to verify the exit. USING THE ACCELERATOR PEDAL 1. Turn the ignition to "ON", with the engine off. 2. Fully press and release the accelerator pedal three times within five seconds. If the "CHANGE ENGINE OIL" message flashes, the system is reset. However, if it stays on , it did not reset. Repeat the procedure. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations Oil Pressure Sender: Locations Lower Right Rear Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 10842 Lower Right Rear Of Engine Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component Information > Locations > Page 10843 Engine Oil Pressure (EOP) Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the left side instrument panel insulator. 2. Remove the left carpet retainers. 3. Disconnect the electrical connector from the switch. 4. Remove the mounting screw. 5. Remove the parking brake indicator switch (1). Installation Procedure 1. Install the parking brake indicator switch (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the mounting screw. ^ Tighten the mounting screw to 3 Nm (26 inch lbs.). 3. Connect the electrical connector to the switch. Check the operation of the switch. 4. Install the left carpet retainers. 5. Install the left side instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service and Repair > Procedures Audible Warning Device Control Module: Procedures MULTIFUNCTION ALARM MODULE REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument cluster trim panel. 2. Remove the screws from the radio delete plate. 3. Remove the radio delete plate from the instrument panel. 4. Disconnect the electrical connector from the multifunction alarm module. 5. Remove the multifunction alarm module from the instrument panel by lifting up and out. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service and Repair > Procedures > Page 10852 1. Install the multifunction alarm module to the instrument panel by pressing in place until fully seated. 2. Connect the electrical connector to the multifunction alarm module. 3. Install the radio delete plate to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the radio delete plate. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the instrument cluster trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service and Repair > Procedures > Page 10853 Audible Warning Device Control Module: Removal and Replacement Multifunction Alarm Module Replacement Removal Procedure 1. Remove the instrument cluster trim panel. 2. Remove the screws from the radio delete plate. 3. Remove the radio delete plate from the instrument panel. 4. Disconnect the electrical connector from the multifunction alarm module. 5. Remove the multifunction alarm module from the instrument panel by lifting up and out. Installation Procedure 1. Install the multifunction alarm module to the instrument panel by pressing in place until fully seated. 2. Connect the electrical connector to the multifunction alarm module. 3. Install the radio delete plate to the instrument panel. Notice: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the radio delete plate. Tighten the screws to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Audible Warning Device Control Module > Component Information > Service and Repair > Procedures > Page 10854 5. Install the instrument cluster trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications Fuel Gauge Sender: Specifications FUEL LEVEL SPECIFICATIONS The values in the table are approximate values based on information obtained from properly operating vehicles. Actual results may vary slightly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 10859 Fuel Gauge Sender: Locations Fuel Pump And Sender Assembly Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 10860 Fuel Pump And Sender Assembly Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 10861 Fuel Gauge Sender: Description and Operation FUEL LEVEL SENSOR The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The powertrain control module (PCM) sends the fuel level information via the class 2 circuit to the instrument panel (IP) cluster. This information is used for the IP fuel gauge and the low fuel warning indicator, if applicable. The PCM also monitors the fuel level input for various diagnostics. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Specifications > Page 10862 Fuel Gauge Sender: Service and Repair FUEL LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Always maintain cleanliness when servicing fuel system components. 1. Remove the fuel sender assembly. 2. Disconnect the fuel level sensor electrical connector. 3. Remove the fuel level sensor (5) from the fuel sender assembly. INSTALLATION PROCEDURE 1. Install the fuel level sensor (5) to the fuel sender assembly. 2. Connect the fuel level sensor electrical connector. 3. Install the fuel sender assembly. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Service and Repair Parking Brake Warning Switch: Service and Repair Park Brake Warning Lamp Switch Replacement Removal Procedure 1. Remove the left side instrument panel insulator. 2. Remove the left carpet retainers. 3. Disconnect the electrical connector from the switch. 4. Remove the mounting screw. 5. Remove the parking brake indicator switch (1). Installation Procedure 1. Install the parking brake indicator switch (1). Notice: Refer to Fastener Notice in Service Precautions. 2. Install the mounting screw. ^ Tighten the mounting screw to 3 Nm (26 inch lbs.). 3. Connect the electrical connector to the switch. Check the operation of the switch. 4. Install the left carpet retainers. 5. Install the left side instrument panel insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Diagrams PRNDL Lamp Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Description and Operation Speedometer Head: Description and Operation SPEEDOMETER The IPC displays the vehicle speed as determined by the IPC. The IPC calculates the mileage based on the class 2 vehicle speed message from the PCM. The IPC calculates vehicle speed based on the class 2 wheel speed message from the EBCM if a loss of communication or malfunction occurs with the PCM. The speedometer defaults to 0 km/h (0 mph) if the IPC detects a loss of class 2 communications with both the PCM and the EBCM. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Description and Operation Tachometer: Description and Operation TACHOMETER The IPC displays the engine speed as determined by the PCM. The IPC receives a class 2 message from the PCM indicating the engine speed. The tachometer will default to 0 rpm if: - The PCM detects a malfunction in the engine speed sensor circuit. - The IPC detects a loss of class 2 communications with the PCM. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Module > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Module: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Monitor Receiver / Transponder > Component Information > Technical Service Bulletins > Tire Monitor System TPM Sensor Information Tire Pressure Monitor Receiver / Transponder: Technical Service Bulletins Tire Monitor System TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs Tire Pressure Sensor: Technical Service Bulletins TPMS System - Service And Re-Learning Sensor IDs INFORMATION Bulletin No.: 10-03-16-001 Date: July 19, 2010 Subject: TPMS System Service and Re-Learning Sensor IDs Models: 2011 and Prior GM Passenger Cars and Light Duty Trucks 2010 and Prior HUMMER H2 2009 and Prior HUMMER H3 2010 and Prior Saturn Models 2009 and Prior Saab 9-7X with Wheel-Mounted Tire Pressure Sensors In the event that the spare tire, which is normally not equipped with a tire pressure monitor (TPM) sensor, is installed in place of one of the road tires and the vehicle is driven above 40 km/h (25 mph) for 20 minutes or more, the TPM indicator icon on the instrument panel cluster (IPC) will flash for approximately one minute and then remain on steady each time the ignition is turned ON, indicating a diagnostic trouble code (DTC) has been set. The driver information center (DIC), if equipped, will also display a SERVICE TIRE MONITOR type message. When the road tire is repaired and reinstalled in the original location, the TPM indicator icon illumination and DIC message may remain displayed until the DTC is cleared. To ensure that the TPM indicator and the DIC message are cleared after service, it is necessary to clear any TPM DTCs using a scan tool. If a scan tool is unavailable, performing the TPM relearn procedure using a TPM diagnostic tool will provide the same results. It is advised to perform the relearn procedure away from other vehicles to prevent picking up a stray sensor signal. If one or more of the TPM sensors are missing or damaged and have been replaced, then the relearn procedure must be performed. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tire Monitoring System > Tire Pressure Sensor > Component Information > Technical Service Bulletins > TPMS System - Service And Re-Learning Sensor IDs > Page 10888 Tire Pressure Sensor: Technical Service Bulletins Tire Monitor System - TPM Sensor Information INFORMATION Bulletin No.: 08-03-16-003 Date: May 12, 2008 Subject: Warranty Reduction - Transfer of Tire Pressure Monitoring (TPM) Sensors to Replacement Wheels and Allowable TPM Sensor Replacements Models: 2000-2009 GM Passenger Cars and Light Duty Trucks (including Saturn) 2003-2009 HUMMER H2 2006-2009 HUMMER H3 2005-2009 Saab 9-7x with On-Wheel TPM Sensors TPM Sensor / Wheel Warranty Reviews During the last warranty review period it was noted that wheels being returned under the GM New Vehicle Warranty were being shipped back to General Motors with the TPM sensor still attached to the wheel. Return rates ran as high as 60% with the TPM sensors still attached. Operational TPM sensors should not be returned to GM and are to be transferred to replacement wheels if they become necessary. Important: Operational TPM Sensors that are returned under warranty to General Motors will be charged back to the dealer.Sensors have a 10 year /150,000 mile (240,000 km) battery life, and should be transferred if one or more wheels are replaced. TPM Valve Stem / Grommet (0-ring) Replacement When the TPM sensors are transferred to new wheels you should replace the component used to seal the TPM sensor stem to the wheel. On sensors with an aluminum stem and visible nut on the outside of the wheel a replacement grommet (0-ring) should be used to assure a proper seal. The sensor retaining nut (except Aveo) should be tightened to 7 N.m (62 lb in) for all vehicles except Pontiac Vibe (4.0 N.m (35.4 lb in)). Important: ^ DO NOT overtorque the retaining nut. Notice: ^ Factory installed TPM Sensors come with plastic aluminum or nickel-plated brass stem caps. These caps should not be changed. Chrome plated steel caps may cause corrosion of aluminum valve stems due to incompatibility of the metals. On current style sensors the entire rubber stem is replaceable. The service interval on the revised TPM sensor with replaceable stem is the same as for any other traditional valve stem. Replace the stem at the time of tire replacement sensor transfer or whenever air seepage is suspected at the valve stem. When replacing the valve stem tighten the screw to 1.3 N.m (11.5 lb in). For either style of TPM sensor see the service parts guide for the correct GM part numbers to order and use. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator Lamp > Component Information > Technical Service Bulletins > Instruments - Reduced PRNDL Display Visibility Transmission Shift Position Indicator Lamp: Technical Service Bulletins Instruments - Reduced PRNDL Display Visibility Bulletin No.: 02-08-42-004A Date: March 30, 2007 INFORMATION Subject: PRNDL Display Reduced Visibility For Approximately One Minute Models: 2007 and Prior Passenger Cars and Trucks (Including Saturn) 2007 and Prior HUMMER H2, H3 2005-2007 Saab 9-7X with Automatic Headlamp Control and Vacuum Fluorescent PRNDL Indicator Instrument Panel Cluster Supercede: This bulletin is being revised to include additional models and model years. Please discard Corporate Bulletin Number 02-08-42-0004 (Section 08 - Body and Accessories). After backing the vehicle out of a garage or dark environment into a daylight environment, the PRNDL display has reduced visibility for approximately one minute. While the vehicle is parked in a dark environment, the sensor for the automatic headlamp/driving lamps senses that it is dark. When the key is turned to the run/start position, the automatic headlamp module will turn all driving lamps, the instrument panel cluster and PRNDL display ON in the night-time mode. The night-time mode intensity of the instrument panel lamps and PRNDL display is controlled by the automatic headlamp module and can be dimmed further by the customer using the dimming control of the headlamp switch. When the customer then moves the vehicle from the dark environment into the bright sunlight, it will take approximately one minute before the headlamp control module recognizes this as true daylight and not just a bright overhead street lamp shining on the sensor. The headlamp control module will then turn the headlamps off and restore the instrument panel and PRNDL display to full brilliance. Without the time delay, the automatic headlamp control module would switch to the night mode (turn on all driving lamps, instrument panel lamps and PRNDL display would dim) each time the vehicle was driven under an overpass or other darkened environment. This is a normal condition and no repair should be attempted. Ensure the instrument panel backlighting control is in the full bright position. This will help alleviate the condition. You may demonstrate to the customer what happens by placing a repair order over the automatic headlamp control light sensor, which will cause the automatic headlamp control module to switch to the night mode in approximately one minute. All driving lamps will come ON, the instrument panel backlight will be dim, and the PRNDL display will also dim to the night setting in conjunction with the position of the headlamp switch dimming control. Demonstrate to the customer the variance in the instrument panel backlighting and PRNDL display while adjusting the headlamp switch dimming control to both ends of its allowable range. Advise the customer to keep the headlight switch dimming control in the highest position to allow viewing of the PRNDL display in a bright environment. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams Ambient Light Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 10897 Ambient Light Sensor: Service and Repair DAYTIME RUNNING LAMPS (DRL) AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the garnish molding from the left windshield pillar. 2. Starting at the left side, carefully lift upwards on the instrument panel (IP) upper trim panel in order to release the retainers from the IP upper trim pad. Work towards the right in order to access the daytime running lamp (DRL) ambient light sensor. 3. Remove the DRL ambient light sensor from the IP upper trim panel by twisting the sensor 1/4 turn counterclockwise. 4. Remove the DRL ambient light sensor from the DRL ambient light sensor connector. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 10898 1. Install the daytime running lamp (DRL) ambient light sensor to the DRL ambient light sensor connector. 2. Position the DRL ambient light sensor to the opening in the instrument panel (IP) upper trim panel. Twist the DRL ambient light sensor 1/4 turn clockwise. 3. Verify that the DRL ambient light sensor wiring harness will not be pinched when the IP upper trim panel is installed. Working from right to left, press down on the IP upper trim panel in order to engage the retainers to the IP upper trim pad. 4. Install the garnish molding to the left windshield pillar. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Backup Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 10903 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Connector Views Backup Lamp: Connector Views Backup Lamp-Left Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Connector Views > Page 10906 Backup Lamp-Right Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Page 10907 Backup Lamp: Description and Operation BACKUP LAMPS The B/U LAMP fuse in the RH I/P fuse block supplies battery positive voltage to the switch terminal of the backup lamps relay. The DIC/RKE fuse supplies battery positive voltage to the backup lamps relay coil terminal. When you place the gear selector lever in the REVERSE position, the powertrain control module (PCM) sends a class 2 message to the body control module (BCM). When these conditions occur, the BCM energizes the reverse lamp relay control circuit, closing the switch contacts, the current flows from the reverse lamp relay switch to the backup lamps. The backup lamps are grounded at G302. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Backup Lamp > Component Information > Diagrams > Page 10908 Backup Lamp: Service and Repair BACKUP LAMP REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Open the rear compartment. 2. Remove the wing nuts from the studs on the rear compartment lid applique. 3. Remove the rear compartment lid applique from the rear compartment lid. 4. Remove the backup lamp sockets from the rear compartment lid applique, turning counterclockwise. 5. Remove the backup lamp bulbs from the sockets. INSTALLATION PROCEDURE 1. Install the backup lamp bulbs to the sockets. 2. Install the sockets to the backup lamp, turning clockwise. 3. Install the rear compartment lid applique to the rear compartment lid. 4. Install the wing nuts to the studs on the rear compartment lid applique and hand tighten. 5. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Brake Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 10913 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Technical Service Bulletins > Page 10914 Brake Lamp: Description and Operation STOP LAMPS The BRAKE SW fuse in the RH I/P fuse block supplies battery positive voltage to the normally-open stop lamp switch. When you press the brake pedal the switch contacts close and battery positive voltage is supplied to the left and right stop lamp assemblies and to the center high mounted stop lamp (CHMSL). The left and right stop lamp along with the CHMSL are grounded at G302. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams Brake Light Switch: Diagrams Stop Lamp Switch, C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 10918 Stop Lamp Switch, C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 10919 Brake Light Switch: Adjustments STOP LAMP SWITCH ADJUSTMENT 1. With the brake pedal in the fully released position, ensure that the stop lamp plunger is fully depressed against the brake pedal shanks. 2. Fully insert the stop lamp switch and the cruise control switch, if equipped, into the brake pedal bracket. 3. Push the brake pedal forward in order to set the brake push rod into the booster. NOTE: Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear. 4. Pull the brake pedal to the rear, against the internal stop. This adjusts both the stop lamp switch and the cruise control switch. 5. Inspect the stop lamp switch for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 10920 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the left instrument panel (I/P) insulator. 2. Disconnect the electrical connector from the stop lamp switch. 3. Remove the stop lamp switch (2) from the brake pedal bracket. INSTALLATION PROCEDURE 1. Install the stop lamp switch (2) to the brake pedal bracket. 2. Connect the electrical connector to the stop lamp switch. 3. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment. 4. Install the left I/P insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams Center High Mounted Stop Lamp (CHMSL) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 10924 Center Mounted Brake Lamp: Service and Repair HIGH MOUNTED STOP LAMP REPLACEMENT REMOVAL PROCEDURE 1. Open the rear compartment. 2. Remove the screw from the high mounted stoplamp bracket. 3. Remove the high mounted stoplamp bracket. 4. Remove the screws from the high mounted stoplamp. 5. Depress the retainers holding the high mounted stoplamp to the inner panel of the compartment lid. 6. Remove the high mounted stoplamp from the rear compartment lid inner panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 10925 7. Disconnect the electrical connector from the high mounted stoplamp. INSTALLATION PROCEDURE 1. Connect the electrical connector to the high mounted stoplamp. 2. Install the high mounted stoplamp pressing in until the retainers are fully seated. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the screws to the high mounted stoplamp. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Component Information > Diagrams > Page 10926 Tighten Tighten the high mounted stoplamp screws to 2 N.m (18 lb in). 4. Install the high mounted stoplamp bracket. 5. Install the screw to the high mounted stoplamp bracket. Tighten Tighten the high mounted stoplamp bracket screw to 2 N.m (18 lb in). 6. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Service and Repair Cornering Lamp: Service and Repair HEADLAMP ASSEMBLY OR HEADLAMP BULB AND/OR CORNERING, SIDEMARKER, PARK, TURN SIGNAL BULB REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Open the hood. 2. Remove the radiator air baffle. 3. Apply light pressure to the headlamp lens to hold the headlamp in place while removing the retainers. 4. Lift up the headlamp retainers to release the headlamp from the upper fascia support. 5. Remove the headlamp from the slots in the upper fascia support. 6. Disconnect the electrical connector from the headlamp. 7. Remove the headlamp from the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Service and Repair > Page 10930 8. Remove the rubber access cover from the headlamp. CAUTION: Refer to Halogen Bulb Caution in Service Precautions. 9. Remove the bulb/socket from the headlamp by rotating counterclockwise. 10. Disconnect the electrical connector from the bulb/socket. INSTALLATION PROCEDURE 1. Connect the electrical connector to the bulb/socket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Service and Repair > Page 10931 2. Install the bulb/socket to the headlamp by rotating clockwise. 3. Install the rubber access cover to the headlamp. 4. Connect the electrical connector to the headlamp. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Service and Repair > Page 10932 5. Position the headlamp to the upper fascia support. 6. Push the headlamp retainers down until fully seated. 7. Install the radiator air baffle. 8. Check and adjust the headlamp aim as necessary. Refer to Headlamp Aiming (Impala)Headlamp Aiming (Monte Carlo). 9. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams Ashtray Lamp Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Ash Tray Lamp > Component Information > Diagrams > Page 10937 Ash Tray Lamp: Service and Repair ASHTRAY LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Open the ashtray drawer. 2. Remove the ashtray from the drawer for accessibility. 3. Remove the ashtray lamp socket from underneath the ashtray drawer, turning counterclockwise. 4. Remove the bulb from the socket. INSTALLATION PROCEDURE 1. Install the bulb to the socket. 2. Install the lamp socket to the ashtray drawer from underneath the ashtray drawer, rotating clockwise. 3. Install the ashtray to the ashtray drawer. 4. Close the ashtray drawer. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair Courtesy Lamp Bulb: Service and Repair ROOF SIDE RAIL LAMP REPLACEMENT REMOVAL PROCEDURE 1. Open the assist handle covers using a small flat bladed tool. 2. Remove the screws from the assist handle. 3. Remove the assist handle. IMPORTANT: The side rail lamp base plate plastic retainers might drop out. Note the location of the retainers. 4. Remove the side rail lamp base plate. 5. Pull the service loop loose from the glue. 6. Disconnect the electrical connector from the side rail lamp. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Page 10941 7. Remove the side rail lamp socket from the base plate by sliding off. 8. Remove the bulb if necessary. INSTALLATION PROCEDURE 1. Install the bulb if necessary. 2. Install the side rail lamp socket to the base plate by sliding on. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Page 10942 3. Connect the electrical connector to the side rail lamp. 4. Install the service loop to glue using foam tape. 5. Align the side rail lamp base plate to the plastic retainers. 6. Position the side rail lamp assist handle to the base plate and the plastic retainers. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information > Service and Repair > Page 10943 7. Install the screws to the side rail lamp assist handle. Tighten Tighten the side rail lamp assist handle screws to 2 N.m (18 lb in). 8. Close the assist handle covers pressing into place until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams I/P Compartment Lamp (Early Production) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Diagrams > Page 10947 Glove Box Lamp: Description and Operation IP COMPARTMENT LAMP The inadvertent power relay provides battery positive voltage to the instrument panel compartment lamp. When you open the IP compartment a switch closes, providing a ground circuit, and the IP compartment lamp illuminates. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Description and Operation Daytime Running Lamp: Description and Operation DAYTIME RUNNING LAMPS (DRL) The ambient light sensor is a light-sensitive transistor that varies its voltage signal to the body control module (BCM) in response to changes in the outside (ambient) light level. When the BCM receives this signal, the BCM turns ON either the DRL lamps or the headlamp relay for auto headlamp operation. Any function or condition that turns ON the headlamps will cancel the DRL operation. Thirty seconds after you start the ignition with the headlamp switch set in the OFF position, the DRL will perform one of two actions: Illuminate the high beam headlamps at a reduced intensity in daylight conditions - Illuminate the low beam headlamps in low light conditions Battery positive voltage is applied at all times from the DRL/EXT LTS fuse in the underhood junction block to the coil side of the DRL relay. When the ambient light sensor indicates a day light condition, the BCM applies a ground to the DRL relay control circuit. This energizes the DRL relay allowing a ground to be applied from G101 through the DRL relay switch side to the left high beam headlamp. When the DRL relay is energized, battery positive voltage is applied from the EXT LTS fuse through the right high beam headlamp, to the left high beam headlamp. The high beam headlamps are now in series, and split the voltage so that the headlamps illuminate a half intensity. The DRL operates when the ignition switch is in the RUN position, and the parking brake is not set or the transmission is not in park. When these conditions have been met and the ambient light sensor indicates daytime conditions, the DRL will illuminate. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams Auxiliary Dome Lamp Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Diagrams > Page 10954 Dome Lamp: Description and Operation AUXILIARY DOME LAMP (SEO, RPO 6C7) An auxiliary dome lamp on Special Equipment Option (SEO) vehicles is mounted to the headliner near the windshield. The auxiliary dome lamp is turned ON using a switch at its base. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Replacement (Impala and Monte Carlo) Dome Lamp: Service and Repair Dome Lamp Replacement (Impala and Monte Carlo) DOME LAMP REPLACEMENT (IMPALA AND MONTE CARLO) REMOVAL PROCEDURE 1. Remove the dome lamp lens from the dome lamp bezel using a small flat bladed tool as a lever on the right side of the dome lamp lens. 2. Remove the dome lamp lens from the dome lamp bezel. 3. Remove the dome lamp bulb. 4. Remove the dome lamp bezel from the headliner using a small flat bladed tool to depress the tab retainers. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Replacement (Impala and Monte Carlo) > Page 10957 5. Remove the dome lamp from the headliner. 6. Remove the dome lamp socket from the dome lamp bezel by squeezing each terminal and pressing out. 7. Remove the dome lamp socket from the dome lamp bezel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Replacement (Impala and Monte Carlo) > Page 10958 8. Remove the dome lamp electrical wiring from back side of the dome lamp bezel. 9. Remove the dome lamp from the vehicle. INSTALLATION PROCEDURE 1. Install the dome lamp socket to the dome lamp bezel by squeezing each terminal and pressing into place until fully seated. 2. Install the dome lamp electrical wiring to back side of the dome lamp bezel. IMPORTANT: The dome lamp bezel will not have a tight fit to the headliner until the dome lamp lens is installed. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Replacement (Impala and Monte Carlo) > Page 10959 3. Install the dome lamp bezel to the headliner pressing into place until the tab retainers are fully seated. 4. Install the dome lamp bulb. 5. Install the dome lamp lens to the dome lamp bezel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Replacement (Impala and Monte Carlo) > Page 10960 6. Inserting the left side of the dome lamp lens with the two retainer tabs first them pressing in the right side until fully seated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Replacement (Impala and Monte Carlo) > Page 10961 Dome Lamp: Service and Repair Dome Lamp Replacement (Impala With SEO, RPO Code 6C7) DOME LAMP REPLACEMENT (IMPALA WITH SEO, RPO 6C7) REMOVAL PROCEDURE 1. Remove the (TRK/ROOF BRP) fuse before starting dome lamp removal procedures. 2. Remove the dome lamp lens from the dome lamp bezel using a small flat bladed tool. 3. Remove the dome lamp bulb. IMPORTANT: Hold the dome lamp bezel in position when removing the screws from the dome lamp bezel. Remove the dome lamp bezel slowly to avoid loosing the dome lamp spacers. 4. Remove the screws from the dome lamp bezel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Replacement (Impala and Monte Carlo) > Page 10962 5. Remove the dome lamp bezel from the headliner. 6. Disconnect the electrical connector if required. INSTALLATION PROCEDURE 1. Connect the electrical connector if required. 2. Position the done lamp spacers and wiring harness ground terminal to the dome lamp bezel and screws. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the dome lamp bezel as an assembly to the dome lamp bracket with the dome lamp switch to the rear. Tighten Tighten the dome lamp screws to 1.5 N.m (17 lb ft). 4. Install the dome lamp bulb. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Dome Lamp > Component Information > Service and Repair > Dome Lamp Replacement (Impala and Monte Carlo) > Page 10963 5. Install the dome lamp lens. 6. Install the (TRK/ROOF BRP) fuse. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations Left Front Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 10968 Fog Lamp Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 10969 Fog/Driving Lamp Switch: Service and Repair FOG LAMP SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the trim plate bezel from the instrument panel (I/P) cluster. 2. Remove the headlamp switch assembly screws. 3. Pull the headlamp switch assembly from the I/P. 4. Disconnect the electrical connector from the fog lamp switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 10970 5. Remove the fog lamp switch from the back of the headlamp switch assembly. INSTALLATION PROCEDURE 1. Install the fog lamp switch through the back of the headlamp switch assembly by pressing the switch into place until fully seated. 2. Connect the electrical connector to the fog lamp switch. 3. Install the headlamp switch assembly to the I/P. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Switch > Component Information > Locations > Page 10971 4. Install the headlamp switch assembly screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the trim plate bezel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Flasher Relay > Component Information > Diagrams Emergency Vehicle Rear Compartment Lid Lamps Relay Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Emergency Vehicle Front Lamps Flasher Emergency Vehicle Front Lamps Flasher Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Emergency Vehicle Front Lamps Flasher > Page 10980 Hazard Warning Flasher: Diagrams Emergency Vehicle Headlamps Flasher Emergency Vehicle Headlamps Flasher, C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Emergency Vehicle Front Lamps Flasher > Page 10981 Emergency Vehicle Headlamps Flasher, C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Emergency Vehicle Front Lamps Flasher > Page 10982 Hazard Warning Flasher: Diagrams Emergency Vehicle Rear Lamps Flasher Emergency Vehicle Rear Lamps Flasher, C1 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Emergency Vehicle Front Lamps Flasher > Page 10983 Emergency Vehicle Rear Lamps Flasher, C1 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Diagrams > Emergency Vehicle Front Lamps Flasher > Page 10984 Emergency Vehicle Rear Lamps Flasher, C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations Left Center Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 10988 Hazard Warning Switch: Diagrams Hazard Switch Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Locations > Page 10989 Hazard Switch Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement Hazard Warning Switch: Service and Repair Hazard Warning Switch Replacement HAZARD WARNING SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Apply the parking brake. 2. Using a small, flat-bladed tool, gently remove the bezel from the ignition lock cylinder. 3. If the vehicle is equipped with a column shift, position the transaxle shift control indicator to 1. 4. Adjust the steering wheel for access. 5. For the Impala, remove the right and the left access covers from the instrument panel (I/P) fuse block. For the Monte Carlo, remove the left access cover from the I/P fuse block. 6. Remove the steering column filler. 7. For the Monte Carlo, open the instrument panel compartment door. 8. Remove the I/P cluster trim plate screws. 9. Start at the left side of the I/P cluster trim plate. Grasp the trim plate and carefully pull rearward. Disengage the I/P cluster trim plate in order to easily access the hazard warning switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement > Page 10992 10. Disconnect the electrical connector from the hazard warning switch. 11. Remove the hazard warning switch from the I/P cluster trim plate. INSTALLATION PROCEDURE 1. Install the hazard warning switch to the I/P cluster trim plate. 2. Connect the electrical connector to the hazard warning switch. 3. Press the I/P cluster trim plate into the I/P trim pad, until all of the retainers are fully seated. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement > Page 10993 4. Install the I/P cluster trim plate screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. For the Monte Carlo, install the left access cover to the I/P fuse block. For the Impala, install the right and the left access covers to the I/P fuse block. 6. Install the steering column filler. 7. For the Monte Carlo, close the I/P compartment door. 8. Reposition the steering wheel to the original position. 9. If the vehicle is equipped with column shift, position the transaxle shift control indicator to Park. 10. Install the bezel to the ignition lock cylinder. 11. Release the parking brake. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement > Page 10994 Hazard Warning Switch: Service and Repair Emergency Vehicle Interior Switch Replacement EMERGENCY VEHICLE INTERIOR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the trim plate bezel from the instrument panel (I/P) cluster. 2. Remove the headlamp switch assembly screws. 3. Pull the headlamp switch assembly from the I/P. 4. Disconnect the electrical connector from the emergency vehicle interior switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement > Page 10995 5. Remove the emergency vehicle interior switch from the back of the headlamp switch assembly. INSTALLATION PROCEDURE 1. Install the emergency vehicle interior switch through the back of the headlamp switch assembly by pressing the switch into place until fully seated. 2. Connect the electrical connector to the emergency vehicle interior switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement > Page 10996 3. Install the headlamp switch assembly to the I/P. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the headlamp switch assembly screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the trim plate bezel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair Headlamp Bulb: Service and Repair HEADLAMP ASSEMBLY OR HEADLAMP BULB AND/OR CORNERING, SIDEMARKER, PARK, TURN SIGNAL BULB REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Open the hood. 2. Remove the radiator air baffle. 3. Apply light pressure to the headlamp lens to hold the headlamp in place while removing the retainers. 4. Lift up the headlamp retainers to release the headlamp from the upper fascia support. 5. Remove the headlamp from the slots in the upper fascia support. 6. Disconnect the electrical connector from the headlamp. 7. Remove the headlamp from the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 11001 8. Remove the rubber access cover from the headlamp. CAUTION: Refer to Halogen Bulb Caution in Service Precautions. 9. Remove the bulb/socket from the headlamp by rotating counterclockwise. 10. Disconnect the electrical connector from the bulb/socket. INSTALLATION PROCEDURE 1. Connect the electrical connector to the bulb/socket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 11002 2. Install the bulb/socket to the headlamp by rotating clockwise. 3. Install the rubber access cover to the headlamp. 4. Connect the electrical connector to the headlamp. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and Repair > Page 11003 5. Position the headlamp to the upper fascia support. 6. Push the headlamp retainers down until fully seated. 7. Install the radiator air baffle. 8. Check and adjust the headlamp aim as necessary. Refer to Headlamp Aiming (Impala) Headlamp Aiming (Monte Carlo). 9. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Lens > Component Information > Technical Service Bulletins > Lighting - Headlamp Polycarbonate Lens Damage Prevention Headlamp Lens: Technical Service Bulletins Lighting - Headlamp Polycarbonate Lens Damage Prevention INFORMATION Bulletin No.: 02-08-42-001D Date: June 21, 2010 Subject: Headlamp Lens Overheating When Covered and Chemical Damage to Exterior Polycarbonate Headlamp Lenses Models: 2011 and Prior GM Passenger Cars and Trucks (Including Saturn) 2010 and Prior HUMMER H2, H3 2009 and Prior Saab 9-7X Supercede: This bulletin is being revised to add model years and to revise the warning statements. Please discard Corporate Bulletin Number 02-08-42-001C (Section 08 - Body and Accessories). The bulletin is being issued to make dealers and customers aware of chemical damage that may be caused to exterior polycarbonate headlamp lenses. Most late model vehicles have these types of headlamp lenses. This material is used because of its temperature and high impact resistance. A variety of chemicals can cause crazing or cracking of the headlamp lens. Headlamp lenses are very sensitive. Care should be exercised to avoid contact with all exterior headlamp lenses when treating a vehicle with any type of chemical, such as those recommended for rail dust removal. Rubbing compound, grease tar and oil removers, tire cleaners, cleaner waxes and even car wash soaps in too high a concentration may also attribute to this condition. This could result in the need to replace the entire headlamp housing. Warning Use only lukewarm or cold water, a soft cloth and a car washing soap to clean exterior lamps and lenses. Also, crazing or deformations of the lens may occur if a shop mat or fender cover is draped over the fender and covers a portion or all of the headlamp assembly while the DRL or headlamps are on. This action restricts the amount of heat dissipated by the headlamps. Warning Care should be taken to not cover headlamps with shop mats or fender covers if the vehicle is being serviced with the headlamps or DRL illuminated. Covering an illuminated lamp can cause excessive heat build up and crazing/deformation of the lens may occur. The degradation of the lens can be unnoticeable at first and eventually become hairline cracks in the lens. In extreme cases, it could cause the lens to deform. This damage can also be caused by aftermarket shields that are often tinted in color. Once a heat buildup is generated by the headlamp, a degradation of the headlamp lens begins. This degradation of the lens can be unnoticeable at first and eventually manifest as spider cracks. In more extreme cases, it will begin to melt the lens of the headlamp. Notice Headlamps damaged by chemicals, improper cleaning, or overheating due to being covered are not covered under the new vehicle warranty. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Located in Junction Block- Left I/P Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Left Front Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11016 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11017 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11018 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11019 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11020 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11021 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11022 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11023 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11024 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11025 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11026 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11027 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11028 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11029 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11030 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11031 Headlamp Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11032 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11033 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11034 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11035 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11036 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11037 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11038 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11039 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11040 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11041 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11042 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11043 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11044 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11045 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11046 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11047 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11048 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11049 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11050 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11051 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11052 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11053 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11054 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11055 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11056 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11057 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11058 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11059 Headlamp Switch: Connector Views Headlamp Switch Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11060 Headlamp Switch Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 11061 Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate bezel. 2. Remove the screws from the headlamp switch housing. 3. Remove the headlamp switch housing from the instrument panel. 4. Disconnect the electrical connector from the headlamp switch. 5. Disconnect the electrical connector from the foglamp switch. 6. Remove the foglamp switch from the headlamp switch housing, using a small flat bladed tool. INSTALLATION PROCEDURE 1. Install the foglamp switch to the headlamp switch housing, pressing into place until fully seated. 2. Connect the electrical connector to the headlamp switch. 3. Connect the electrical connector to the foglamp switch. 4. Install the headlamp housing switch to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the screws to the headlamp housing switch. Tighten Tighten the headlamp housing switch screws to 2 N.m (18 lb in). 6. Install the instrument panel cluster trim plate bezel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Connector Views License Plate Lamp: Connector Views License Lamp-Left Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Connector Views > Page 11066 License Lamp-Right Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 11067 License Plate Lamp: Description and Operation PARK, TAIL, MARKER LAMPS, AND LICENSE The park, tail and marker lamps, including the license lamps, turn on when the headlamp switch is placed in either the PARK or the HEAD position, or anytime the headlamps are requested. The RT I/P #1 fuse in the RH I/P fuse block supplies battery positive voltage to both the park lamp relay switch contacts and to the park lamp relay coil circuit. The park lamp relay coil is controlled by the body control module (BCM). When the headlamp switch is placed in the PARK position, the BCM energizes the park lamp relay coil control circuit. Current flows from the park lamp relay switch to both front and rear park lamp fuses and to their respective park/tail lamps. The front park lamps are grounded at G101. The rear park lamps are grounded at G302. The license plate lamps are a part of the rear park lamp circuit and are grounded at G302. The inadvertent power control feature prevents the park lamps from remaining on more than 10 minutes if left on. If the park lamps are turned on after the ignition switch has been turned OFF, or is in the ACCY position, they will remain on until turned off or until the battery runs dead. A surveillance mode is available in Special Equipment Option (SEO) vehicles. The headlamps and park lamps may be disabled by using the emergency vehicle interior lamp switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > License Plate Lamp > Component Information > Diagrams > Page 11068 License Plate Lamp: Service and Repair LICENSE LAMP REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Remove the screws from the license plate lamp. 2. Remove the license plate lamp from the rear bumper fascia. 3. Remove the license plate lamp socket, turning counterclockwise. 4. Remove the bulb from the license plate lamp socket. INSTALLATION PROCEDURE 1. Install the bulb to the license plate lamp socket. 2. Install the license plate lamp socket, turning clockwise. 3. Install the license plate lamp to the rear bumper fascia. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the screws to the license plate lamp. Tighten Tighten the license plate lamp screws to 2 N.m (18 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair Marker Lamp Bulb: Service and Repair HEADLAMP ASSEMBLY OR HEADLAMP BULB AND/OR CORNERING, SIDEMARKER, PARK, TURN SIGNAL BULB REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Open the hood. 2. Remove the radiator air baffle. 3. Apply light pressure to the headlamp lens to hold the headlamp in place while removing the retainers. 4. Lift up the headlamp retainers to release the headlamp from the upper fascia support. 5. Remove the headlamp from the slots in the upper fascia support. 6. Disconnect the electrical connector from the headlamp. 7. Remove the headlamp from the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Page 11073 8. Remove the rubber access cover from the headlamp. CAUTION: Refer to Halogen Bulb Caution in Service Precautions. 9. Remove the bulb/socket from the headlamp by rotating counterclockwise. 10. Disconnect the electrical connector from the bulb/socket. INSTALLATION PROCEDURE 1. Connect the electrical connector to the bulb/socket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Page 11074 2. Install the bulb/socket to the headlamp by rotating clockwise. 3. Install the rubber access cover to the headlamp. 4. Connect the electrical connector to the headlamp. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Marker Lamp > Marker Lamp Bulb > Component Information > Service and Repair > Page 11075 5. Position the headlamp to the upper fascia support. 6. Push the headlamp retainers down until fully seated. 7. Install the radiator air baffle. 8. Check and adjust the headlamp aim as necessary. Refer to Headlamp Aiming (Impala)Headlamp Aiming (Monte Carlo). 9. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair Parking Light Bulb: Service and Repair HEADLAMP ASSEMBLY OR HEADLAMP BULB AND/OR CORNERING, SIDEMARKER, PARK, TURN SIGNAL BULB REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Open the hood. 2. Remove the radiator air baffle. 3. Apply light pressure to the headlamp lens to hold the headlamp in place while removing the retainers. 4. Lift up the headlamp retainers to release the headlamp from the upper fascia support. 5. Remove the headlamp from the slots in the upper fascia support. 6. Disconnect the electrical connector from the headlamp. 7. Remove the headlamp from the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair > Page 11080 8. Remove the rubber access cover from the headlamp. CAUTION: Refer to Halogen Bulb Caution in Service Precautions. 9. Remove the bulb/socket from the headlamp by rotating counterclockwise. 10. Disconnect the electrical connector from the bulb/socket. INSTALLATION PROCEDURE 1. Connect the electrical connector to the bulb/socket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair > Page 11081 2. Install the bulb/socket to the headlamp by rotating clockwise. 3. Install the rubber access cover to the headlamp. 4. Connect the electrical connector to the headlamp. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service and Repair > Page 11082 5. Position the headlamp to the upper fascia support. 6. Push the headlamp retainers down until fully seated. 7. Install the radiator air baffle. 8. Check and adjust the headlamp aim as necessary. Refer to Headlamp Aiming (Impala)Headlamp Aiming (Monte Carlo). 9. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Hazard Flasher Relay > Component Information > Diagrams Emergency Vehicle Rear Compartment Lid Lamps Relay Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay > Component Information > Locations Headlamp Relay: Locations Located in Junction Block- Left I/P Location View Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams Ambient Light Sensor Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 11094 Ambient Light Sensor: Service and Repair DAYTIME RUNNING LAMPS (DRL) AMBIENT LIGHT SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the garnish molding from the left windshield pillar. 2. Starting at the left side, carefully lift upwards on the instrument panel (IP) upper trim panel in order to release the retainers from the IP upper trim pad. Work towards the right in order to access the daytime running lamp (DRL) ambient light sensor. 3. Remove the DRL ambient light sensor from the IP upper trim panel by twisting the sensor 1/4 turn counterclockwise. 4. Remove the DRL ambient light sensor from the DRL ambient light sensor connector. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Diagrams > Page 11095 1. Install the daytime running lamp (DRL) ambient light sensor to the DRL ambient light sensor connector. 2. Position the DRL ambient light sensor to the opening in the instrument panel (IP) upper trim panel. Twist the DRL ambient light sensor 1/4 turn clockwise. 3. Verify that the DRL ambient light sensor wiring harness will not be pinched when the IP upper trim panel is installed. Working from right to left, press down on the IP upper trim panel in order to engage the retainers to the IP upper trim pad. 4. Install the garnish molding to the left windshield pillar. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams Brake Light Switch: Diagrams Stop Lamp Switch, C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 11099 Stop Lamp Switch, C2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 11100 Brake Light Switch: Adjustments STOP LAMP SWITCH ADJUSTMENT 1. With the brake pedal in the fully released position, ensure that the stop lamp plunger is fully depressed against the brake pedal shanks. 2. Fully insert the stop lamp switch and the cruise control switch, if equipped, into the brake pedal bracket. 3. Push the brake pedal forward in order to set the brake push rod into the booster. NOTE: Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear. 4. Pull the brake pedal to the rear, against the internal stop. This adjusts both the stop lamp switch and the cruise control switch. 5. Inspect the stop lamp switch for proper adjustment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Diagrams > Page 11101 Brake Light Switch: Service and Repair STOP LAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the left instrument panel (I/P) insulator. 2. Disconnect the electrical connector from the stop lamp switch. 3. Remove the stop lamp switch (2) from the brake pedal bracket. INSTALLATION PROCEDURE 1. Install the stop lamp switch (2) to the brake pedal bracket. 2. Connect the electrical connector to the stop lamp switch. 3. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment. 4. Install the left I/P insulator. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations Combination Switch: Locations Steering Wheel Controls (Radio) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 11105 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 11106 Steering Wheel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch > Component Information > Locations > Page 11107 Steering Wheel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations Left Front Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 11111 Fog Lamp Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 11112 Fog/Driving Lamp Switch: Service and Repair FOG LAMP SWITCH REPLACEMENT - FRONT REMOVAL PROCEDURE 1. Remove the trim plate bezel from the instrument panel (I/P) cluster. 2. Remove the headlamp switch assembly screws. 3. Pull the headlamp switch assembly from the I/P. 4. Disconnect the electrical connector from the fog lamp switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 11113 5. Remove the fog lamp switch from the back of the headlamp switch assembly. INSTALLATION PROCEDURE 1. Install the fog lamp switch through the back of the headlamp switch assembly by pressing the switch into place until fully seated. 2. Connect the electrical connector to the fog lamp switch. 3. Install the headlamp switch assembly to the I/P. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Fog/Driving Lamp Switch > Component Information > Locations > Page 11114 4. Install the headlamp switch assembly screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the trim plate bezel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations Left Center Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 11118 Hazard Warning Switch: Diagrams Hazard Switch Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Locations > Page 11119 Hazard Switch Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement Hazard Warning Switch: Service and Repair Hazard Warning Switch Replacement HAZARD WARNING SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Apply the parking brake. 2. Using a small, flat-bladed tool, gently remove the bezel from the ignition lock cylinder. 3. If the vehicle is equipped with a column shift, position the transaxle shift control indicator to 1. 4. Adjust the steering wheel for access. 5. For the Impala, remove the right and the left access covers from the instrument panel (I/P) fuse block. For the Monte Carlo, remove the left access cover from the I/P fuse block. 6. Remove the steering column filler. 7. For the Monte Carlo, open the instrument panel compartment door. 8. Remove the I/P cluster trim plate screws. 9. Start at the left side of the I/P cluster trim plate. Grasp the trim plate and carefully pull rearward. Disengage the I/P cluster trim plate in order to easily access the hazard warning switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement > Page 11122 10. Disconnect the electrical connector from the hazard warning switch. 11. Remove the hazard warning switch from the I/P cluster trim plate. INSTALLATION PROCEDURE 1. Install the hazard warning switch to the I/P cluster trim plate. 2. Connect the electrical connector to the hazard warning switch. 3. Press the I/P cluster trim plate into the I/P trim pad, until all of the retainers are fully seated. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement > Page 11123 4. Install the I/P cluster trim plate screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. For the Monte Carlo, install the left access cover to the I/P fuse block. For the Impala, install the right and the left access covers to the I/P fuse block. 6. Install the steering column filler. 7. For the Monte Carlo, close the I/P compartment door. 8. Reposition the steering wheel to the original position. 9. If the vehicle is equipped with column shift, position the transaxle shift control indicator to Park. 10. Install the bezel to the ignition lock cylinder. 11. Release the parking brake. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement > Page 11124 Hazard Warning Switch: Service and Repair Emergency Vehicle Interior Switch Replacement EMERGENCY VEHICLE INTERIOR SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the trim plate bezel from the instrument panel (I/P) cluster. 2. Remove the headlamp switch assembly screws. 3. Pull the headlamp switch assembly from the I/P. 4. Disconnect the electrical connector from the emergency vehicle interior switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement > Page 11125 5. Remove the emergency vehicle interior switch from the back of the headlamp switch assembly. INSTALLATION PROCEDURE 1. Install the emergency vehicle interior switch through the back of the headlamp switch assembly by pressing the switch into place until fully seated. 2. Connect the electrical connector to the emergency vehicle interior switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Service and Repair > Hazard Warning Switch Replacement > Page 11126 3. Install the headlamp switch assembly to the I/P. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the headlamp switch assembly screws. Tighten Tighten the screws to 2 N.m (18 lb in). 5. Install the trim plate bezel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Left Front Of Instrument Panel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11132 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11133 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11134 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11135 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11136 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11137 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11138 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11139 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11140 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11141 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11142 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11143 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11144 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11145 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11146 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11147 Headlamp Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11148 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11149 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11150 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11151 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11152 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11153 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11154 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11155 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11156 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11157 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11158 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11159 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11160 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11161 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11162 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11163 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11164 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11165 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11166 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11167 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11168 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11169 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11170 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11171 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11172 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11173 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11174 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11175 Headlamp Switch: Connector Views Headlamp Switch Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11176 Headlamp Switch Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 11177 Headlamp Switch: Service and Repair HEADLAMP SWITCH REPLACEMENT REMOVAL PROCEDURE 1. Remove the instrument panel cluster trim plate bezel. 2. Remove the screws from the headlamp switch housing. 3. Remove the headlamp switch housing from the instrument panel. 4. Disconnect the electrical connector from the headlamp switch. 5. Disconnect the electrical connector from the foglamp switch. 6. Remove the foglamp switch from the headlamp switch housing, using a small flat bladed tool. INSTALLATION PROCEDURE 1. Install the foglamp switch to the headlamp switch housing, pressing into place until fully seated. 2. Connect the electrical connector to the headlamp switch. 3. Connect the electrical connector to the foglamp switch. 4. Install the headlamp housing switch to the instrument panel. NOTE: Refer to Fastener Notice in Service Precautions. 5. Install the screws to the headlamp housing switch. Tighten Tighten the headlamp housing switch screws to 2 N.m (18 lb in). 6. Install the instrument panel cluster trim plate bezel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Steering Wheel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 11181 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 11182 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 11183 Steering Wheel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Locations > Page 11184 Steering Wheel Controls (Radio) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement Turn Signal Switch: Service and Repair Multifunction Switch Replacement Multifunction, Turn Signal Switch Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the upper and lower trim covers. Important: The abrasion sleeve located on the steering column wire harness assembly must be reinstalled. Make note of what connector is coming out of the abrasion sleeve for installation purposes. 3. Remove the wire harness assembly (1) from the wire harness strap (2). 4. Disconnect the turn signal and multifunction switch assembly connector from the SIR system coil connector. 5. Slide the 2 connectors (2) of the turn signal and multifunction switch assembly out of the bulkhead connector (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 11187 6. Remove the 2 pan head tapping screws (1) and (3) from the turn signal and multifunction switch assembly (2). 7. Remove the turn signal and multifunction switch assembly (2) from the steering column tilt head assembly. Installation Procedure 1. Install the turn signal and multifunction switch assembly (2) onto the steering column tilt head assembly. Notice: Refer to Fastener Notice in Service Precautions. Important: Be sure that the electrical contact of the turn signal and multifunction switch assembly (2) rests on the turn signal cancel cam assembly. 2. Screw the 2 pan head tapping screws (1) and (3) into the turn signal and multifunction assembly (2). ^ Tighten the top pan head tapping screw (1) to 3 Nm (27 in. lbs.). ^ Tighten the side pan head tapping screw (3) to 7 Nm (62 in. lbs.). 3. Slide the 2 connectors (2) of the turn signal and multifunction switch assembly into the bulkhead connector (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 11188 4. Connect the turn signal and multifunction switch assembly connector to the SIR coil connector. Important: The abrasion sleeve must be installed back onto the steering column wire harness assembly. The ignition lock cylinder case wires and connector must be hanging out of the middle of the abrasion sleeve. 5. Install the wire harness assembly (1) into the wire harness strap (2). 6. Install the upper and lower trim covers. 7. Enable the SIR system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 11189 Turn Signal Switch: Service and Repair Turn Signal Cancel Cam and Steering Shaft Upper Bearing Spring Turn Signal Cancel Cam and Steering Shaft Upper Bearing Spring Replacement ^ Tools Required J 23653-SIR Steering Column Lock Plate Compressor - J 42137 Cam Orientation Plate Adapter Removal Procedure 1. Disconnect the battery negative cable. Caution: Refer to SIR Caution in Service Precautions. 2. Disable the SIR system. 3. Remove the inflator module. 4. Remove the steering wheel. 5. Remove the SIR coil from the steering column upper shaft. 6. Allow the SIR coil to hang. 7. Remove the wave washer (1) from the steering shaft (2). 8. Compress the shaft lock plate using J23653-SIR and J42137. 9. Remove the bearing retainer (1) from the steering shaft. 10. Remove J23653-S/R and J42137 from the steering shaft. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 11190 11. Remove the shaft lock shield (5) from the steering shaft. 12. Remove the turn signal cancel cam (4) from the steering shaft. 13. Remove the upper bearing spring (3) from the steering shaft. 14. Remove the upper bearing inner race seat (2) from the steering shaft. 15. Remove the inner race (1) from the steering shaft. Installation Procedure 1. Lubricate the inner race (1) with GM P/N 12345718 (Canadian P/N 10953516). 2. Install the inner race (1) onto the steering shaft. 3. Install the upper bearing inner race seat (2) onto the steering shaft. 4. Install the upper bearing spring (3) onto the steering shaft. 5. Lubricate the lower brass surface of the turn signal cancel cam (4) with GM P/N 12377900 (Canadian P/N 10953529). 6. Install the turn signal cancel cam (4) onto the steering shaft. 7. Install the shaft lock shield (5) onto the steering shaft. 8. Compress the shaft lock shield (2) using J 23653-SIR and J 42137. 9. Install the new bearing retainer (1) onto the steering shaft. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 11191 10. Firmly seat the bearing retainer (1) into the groove on the steering shaft. 11. Remove J 23653-SIR and J 42137from the steering shaft. 12. Install the wave washer (1) onto the steering shaft (2). 13. Install the SIR coil. 14. Install the steering wheel. 15. Install the inflator module. 16. Enable the SIR system. 17. Connect the battery negative cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams Spot Lamp: Diagrams Spot Lamp-Left Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Page 11195 Spot Lamp-Right Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Page 11196 Spot Lamp: Description and Operation SPOT LAMPS AND FRONT LAMPS (SEO, RPO 9C1, 9C6, 7X6 AND 7X7) The spot lamp system on Special Equipment Option (SEO) vehicles consists of either one left spot lamp (RPO 7X6), or two left and right spot lamps (RPO 7X7). The spot lamps are mounted to either the left or right hand windshield pillars and contain their own ON/OFF switch. Battery positive voltage is supplied to the spot lamps through their own respective fuses. All other wiring is blunt-ended to be used on SEO vehicles as necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Diagrams > Page 11197 Spot Lamp: Adjustments SPOT LAMP TRAVEL ADJUSTMENT (SEO) (IMPALA With RPO Code 7X6, 7X7) 1. Loosen the spot lamp bracket clamp bolt. 2. Grasp the spot lamp. Slowly rotate the spot lamp inboard until the shaft contacts the parkstop position. 3. Rotate the spot lamp slowly outboard to 5 degrees past the vertical position in order for the backstop to be in motion and the outer tube shaft to rotate. 4. Tighten the bracket clamp bolt sufficiently, in order to prevent the outer shaft tube from rotating while the spotlamp is moving between the stop positions. 5. Rotate the spot lamp head inboard to the parkstop position in order to prevent the spot lamp from coming in contact with the body components. 6. Position the parkstop of the shaft in order to rotate the spot lamp on its axis, clearing the nearest body components by 13-0.5 mm (0.50-0.02 in). NOTE: Refer to Fastener Notice in Service Precautions. 7. Tighten the bracket clamp screw when the parkstop has been set, in order to prevent rotation of the spot lamp shaft. Tighten Tighten the spot lamp bracket clamp bolt to 6 N.m (53 lb in). 8. Adjust the spot lamp head clamping bolt, in order to easily rotate the spot lamp (120 degrees) in any adjustable position between the parkstop and the backstop positions. The total motion of the spot lamp is approximately 90 degrees. Tighten Tighten the spot lamp head clamping bolt to 2.5 N.m (22 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Service and Repair > Spot Lamp Replacement (SEO) (Impala With RPO Code 7X6, 7X7) Spot Lamp: Service and Repair Spot Lamp Replacement (SEO) (Impala With RPO Code 7X6, 7X7) SPOT LAMP REPLACEMENT (SEO) (IMPALA With RPO Code 7X6, 7X7) REMOVAL PROCEDURE 1. Remove the spot lamp wiring harness push-in retainer from the windshield garnish molding, using a small flat bladed tool. 2. Disconnect the electrical connector. 3. Remove the spot lamp handle wedge key screw from the spot lamp handle. Loosen the wedge key screw a few turns then with a light tap with a suitable hammer to the wedge key screw will loosen it from the spot lamp outer tube shaft. 4. Remove the spot lamp handle from the outer tube shaft. 5. Remove the rubber grommet from the outer tube shaft. 6. Loosen the spot lamp bracket set screw. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Service and Repair > Spot Lamp Replacement (SEO) (Impala With RPO Code 7X6, 7X7) > Page 11200 7. Pull the spot lamp with the outer tube shaft out of the spot lamp mounting bracket and set aside. 8. Remove the spot lamp mounting bracket screws. 9. Remove the mounting bracket and the gasket from the windshield pillar. 10. Clean the mounting surface of the windshield pillar. INSTALLATION PROCEDURE IMPORTANT: This method of installation will stop the chance of any alignment and binding problems. 1. Install the mounting bracket and the gasket on to the spotlamp outer tube shaft. 2. Apply a small amount of RTV sealer GM P/N 12345336 or Canadian P/N 12346286 or equivalent to the screw holes on the windshield pillar. 3. Install the mounting bracket , the gasket and the spotlamp outer tube shaft through the windshield pillar. NOTE: Refer to Fastener Notice in Service Precautions. 4. Install the spot lamp mounting bracket screws. Tighten Tighten the spot lamp mounting bracket screws to 3.5 N.m (31 lb in). 5. Rotate the spot lamp to the upright position. Point the spot lamp forward. 6. Tighten the spot lamp mounting bracket set screw just enough in order to firmly hold the spot lamp in the upright position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Service and Repair > Spot Lamp Replacement (SEO) (Impala With RPO Code 7X6, 7X7) > Page 11201 7. Install the rubber grommet to the outer tube shaft. 8. Install the spot lamp handle onto the outer tube shaft in the vertical down position until the handle bottoms out, and the flat detent on the outer tube shaft is exposed through the wedge key screw hole. 9. Install the spot lamp wedge key screw. Tighten Tighten the spot lamp wedge key screw to 7.5 N.m (66 lb in). 10. Connect the electrical connector. 11. Install the spot lamp wiring harness push-in retainer to the windshield garnish molding, pressing in until fully seated. 12. Inspect the spot lamp for proper operation. - The handle must rotate the spotlamp approximately 90 degrees about the spot lamp shaft axis from the parked position to the vertical position. - The spot lamp head must rotate 360 degrees about its axis. - The spot lamp must able to be turned ON/OFF independent of the ignition switch. 13. If spot lamp adjustment and/or electrical diagnosis are required, refer to the following procedures. - For spot lamp travel adjustment, refer to Spot Lamp Travel Adjustment (SEO) (Impala RPO 7X6, 7X7). - For electrical diagnosis, refer to Power Distribution Schematics in Diagnostic Aids. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Service and Repair > Spot Lamp Replacement (SEO) (Impala With RPO Code 7X6, 7X7) > Page 11202 Spot Lamp: Service and Repair Spot Lamp Bulb Replacement (SEO)(Impala With RPO Code 7X6, 7X7) SPOT LAMP BULB REPLACEMENT (SEO) (IMPALA With RPO Code 7X6, 7X7) REMOVAL PROCEDURE 1. Remove the spot lamp wiring harness push-in retainer from the windshield garnish molding, using a small flat bladed tool. 2. Disconnect the electrical connector. 3. Remove the screw from the spot lamp bezel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Service and Repair > Spot Lamp Replacement (SEO) (Impala With RPO Code 7X6, 7X7) > Page 11203 4. Remove the spot lamp bezel from the spot lamp. 5. Remove the lamp from the spot lamp. 6. Remove spot lamp bulb retaining clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Service and Repair > Spot Lamp Replacement (SEO) (Impala With RPO Code 7X6, 7X7) > Page 11204 7. Remove the spot lamp bulb from the spot lamp. 8. Disconnect the the spot lamp bulb electrical connector. INSTALLATION PROCEDURE 1. Connect the spot lamp bulb electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Service and Repair > Spot Lamp Replacement (SEO) (Impala With RPO Code 7X6, 7X7) > Page 11205 2. Install the spot lamp bulb to the spot lamp. 3. Install the spot lamp bulb retaining clip. IMPORTANT: The spot lamp assembly must be clocked in the UP position, refer to the emblem on the face of the lamp. 4. Holding the spot lamp in position, install the spot lamp bezel to the spot lamp. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Spot Lamp > Component Information > Service and Repair > Spot Lamp Replacement (SEO) (Impala With RPO Code 7X6, 7X7) > Page 11206 5. Install the spot lamp bezel screws. Tighten Tighten the spot lamp bezel screws to 2 N.m (18 lb in). 6. Using a small flat bladed tool, install the spot lamp wiring harness push-in retainer to the windshield garnish molding. 7. Connect the electrical connector. 8. Inspect the spot lamp for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement Tail Lamp: Technical Service Bulletins Lighting - Exterior Lamp Condensation and Replacement INFORMATION Bulletin No.: 01-08-42-001H Date: January 05, 2011 Subject: Exterior Lamp Condensation and Replacement Guidelines Models: 2011 and Prior GM Passenger Cars and Trucks (including Saturn) Supercede: This bulletin is being revised to add the 2011 model year. Please discard Corporate Bulletin Number 01-08-42-001G (Section 08 - Body and Accessories). The following information is being provided to better define the causes of condensation in exterior lamps and includes guidelines for determining the difference between a lamp with a normal atmospheric condition (condensation) and a lamp with a water leak. Some exterior lamps, such as cornering, turn signal, backup, headlamps or tail lamps may exhibit very small droplets of water, a fine mist or white fog (condensation) on the inside of the lamp lens. This may be more noticeable on lamps with "multi-lens" designs and may be normal during certain weather conditions. Condensation occurs when the air inside the lamp assembly, through atmospheric changes, reaches the "dew point". When this takes place, the moisture in the air within the lamp assembly condenses, creating a fine mist or white fog on the inside surface of the lamp lens. Most exterior lamps on General Motors vehicles use a vented design and feature a replaceable bulb assembly. They are designed to remove any accumulated moisture vapor by expelling it through a vent system. The vent system operates at all times, however, it is most effective when the lamps are ON or when the vehicle is in motion. Depending on the size, shape and location of the lamp on the vehicle, and the atmospheric conditions occurring, the amount of time required to clear the lamp may vary from 2 to 6 hours. Completely sealed headlamp assemblies (sealed beams) are still used on a limited number of models being manufactured today. These lamps require the replacement of the complete lamp assembly if a bulb filament burns out. Condensation 2006 TrailBlazer Shown A Fine Mist or White Fog on the Inside Surface of the Lamp Lens Occurring After a Period of High Humidity - May be located primarily in the lens corners (near the vents) and SHOULD NOT cover more than half the lens surface. - The condition should clear of moisture when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a SIMILAR performance. If the above conditions are noted, the customer should be advised that replacement of a lamp assembly may not correct this condition. Water Leak New Style Pickup Shown Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Technical Service Bulletins > Lighting - Exterior Lamp Condensation and Replacement > Page 11211 Numerous & Various Size Drops of Water Collecting on the Inside Surface of the Lamp Lens After the Vehicle Has Been Exposed to Rain or a Car Washing Environment - A condition that covers more than half the surface of the lamp lens. - An accumulation of water in the bottom of the lamp assembly. - A condition that WON'T clear when the vehicle is parked in a dry environment, or when the vehicle is driven with the lights ON. - A comparison of the equivalent lamp on the opposing side of the vehicle indicates a different performance. Any of the above conditions would indicate the need to service the lens or lamp assembly. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Connector Views Tail Lamp: Connector Views Tail Lamp-Left Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Connector Views > Page 11214 Tail Lamp-Right Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 11215 Tail Lamp: Description and Operation PARK, TAIL, MARKER LAMPS, AND LICENSE The park, tail and marker lamps, including the license lamps, turn on when the headlamp switch is placed in either the PARK or the HEAD position, or anytime the headlamps are requested. The RT I/P #1 fuse in the RH I/P fuse block supplies battery positive voltage to both the park lamp relay switch contacts and to the park lamp relay coil circuit. The park lamp relay coil is controlled by the body control module (BCM). When the headlamp switch is placed in the PARK position, the BCM energizes the park lamp relay coil control circuit. Current flows from the park lamp relay switch to both front and rear park lamp fuses and to their respective park/tail lamps. The front park lamps are grounded at G101. The rear park lamps are grounded at G302. The license plate lamps are a part of the rear park lamp circuit and are grounded at G302. The inadvertent power control feature prevents the park lamps from remaining on more than 10 minutes if left on. If the park lamps are turned on after the ignition switch has been turned OFF, or is in the ACCY position, they will remain on until turned off or until the battery runs dead. A surveillance mode is available in Special Equipment Option (SEO) vehicles. The headlamps and park lamps may be disabled by using the emergency vehicle interior lamp switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 11216 Tail Lamp: Service and Repair TAIL LAMP REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Open the rear compartment. 2. Remove wingnut and pull back the rear compartment trim panel from the tail lamp. 3. Remove the wingnuts from the tail lamp. 4. Remove the tail lamp from the rear body panel. 5. Disconnect the electrical connector from the tail lamp. 6. Remove the tail lamp socket, turning counterclockwise. 7. Remove the bulb from the tail lamp socket. 8. Remove the sidemarker lamp socket, turning counterclockwise. 9. Remove the bulb from the sidemarker lamp socket. INSTALLATION PROCEDURE 1. Install the bulb to the tail lamp socket. 2. Install the bulb to the sidemarker lamp socket. 3. Install the sidemarker lamp socket, turning clockwise. 4. Install the tail lamp socket, turning clockwise. 5. Connect the electrical connector to the tail lamp. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Tail Lamp > Component Information > Diagrams > Page 11217 6. Install the tail lamp to the rear body panel. 7. Install the wingnuts to the tail lamp. 8. Pull back the rear compartment trim panel to the tail lamp and install the wingnut. 9. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Description and Operation Trunk Lamp: Description and Operation REAR COMPARTMENT LAMP The inadvertent power relay provides battery positive voltage to the rear compartment lamp. When you open the rear compartment a switch closes, providing a ground circuit and the rear compartment lamp illuminates. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Service and Repair > Rear Compartment Lamp Replacement Trunk Lamp: Service and Repair Rear Compartment Lamp Replacement REAR COMPARTMENT LAMP REPLACEMENT REMOVAL PROCEDURE 1. Open the rear compartment. 2. Remove the rear compartment lamp using a small flat-bladed tool to release the retaining tabs. 3. Remove the bulb from the rear compartment lamp socket. INSTALLATION PROCEDURE 1. Install the bulb to the rear compartment lamp socket. 2. Install the rear compartment lamp, pressing into place until full seated. 3. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Service and Repair > Rear Compartment Lamp Replacement > Page 11223 Trunk Lamp: Service and Repair Compartment Lid Lamp Replacement - Rear (SEO) COMPARTMENT LID LAMP REPLACEMENT - REAR (SEO) (IMPALA With RPO Code T53) REMOVAL PROCEDURE 1. Open the rear compartment. 2. Disconnect the electrical connectors from the rear compartment lid lamp(s). 3. Disconnect the electrical connector from the flasher fuse (1). 4. Remove the flasher fuse (1) if required. 5. Drill out the rivets from the rear compartment lid lamp bracket(s). 6. Remove the rear compartment lid lamp(s) from the rear compartment lid. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Service and Repair > Rear Compartment Lamp Replacement > Page 11224 1. Position the rear compartment lid lamp(s) from the rear compartment lid. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the rivets to the rear compartment lid lamp bracket(s). 3. Install the flasher fuse (1) if required. 4. Connect the electrical connector to the flasher fuse (1). 5. Connect the electrical connectors to the rear compartment lid lamp(s). 6. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Service and Repair > Rear Compartment Lamp Replacement > Page 11225 Trunk Lamp: Service and Repair Compartment Lid Lamp Lens and Bulb - Rear (SEO) COMPARTMENT LID LAMP LENS AND BULB - REAR (SEO) (IMPALA With RPO Code T53) REMOVAL PROCEDURE 1. Open the rear compartment. 2. Remove the lens from the rear compartment lid lamp. Inserted a small coin under the rear compartment lid lamp lens and then twist the coin. 3. Remove the bulb from the rear compartment lid lamp socket. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Trunk Lamp > Component Information > Service and Repair > Rear Compartment Lamp Replacement > Page 11226 1. Install the bulb to the rear compartment lid lamp socket. 2. Install the lens to the rear compartment lid lamp, pressing into place until fully seated. 3. Close the rear compartment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations Combination Switch: Locations Steering Wheel Controls (Radio) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 11231 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 11232 Steering Wheel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information > Locations > Page 11233 Steering Wheel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair Turn Signal Bulb: Service and Repair HEADLAMP ASSEMBLY OR HEADLAMP BULB AND/OR CORNERING, SIDEMARKER, PARK, TURN SIGNAL BULB REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Open the hood. 2. Remove the radiator air baffle. 3. Apply light pressure to the headlamp lens to hold the headlamp in place while removing the retainers. 4. Lift up the headlamp retainers to release the headlamp from the upper fascia support. 5. Remove the headlamp from the slots in the upper fascia support. 6. Disconnect the electrical connector from the headlamp. 7. Remove the headlamp from the vehicle. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Page 11238 8. Remove the rubber access cover from the headlamp. CAUTION: Refer to Halogen Bulb Caution in Service Precautions. 9. Remove the bulb/socket from the headlamp by rotating counterclockwise. 10. Disconnect the electrical connector from the bulb/socket. INSTALLATION PROCEDURE 1. Connect the electrical connector to the bulb/socket. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Page 11239 2. Install the bulb/socket to the headlamp by rotating clockwise. 3. Install the rubber access cover to the headlamp. 4. Connect the electrical connector to the headlamp. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component Information > Service and Repair > Page 11240 5. Position the headlamp to the upper fascia support. 6. Push the headlamp retainers down until fully seated. 7. Install the radiator air baffle. 8. Check and adjust the headlamp aim as necessary. Refer to Headlamp Aiming (Impala)Headlamp Aiming (Monte Carlo). 9. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations Turn Signal Switch: Locations Steering Wheel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11244 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11245 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11246 Steering Wheel Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Locations > Page 11247 Steering Wheel Controls (Radio) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement Turn Signal Switch: Service and Repair Multifunction Switch Replacement Multifunction, Turn Signal Switch Replacement Removal Procedure Caution: Refer to SIR Caution in Service Precautions. 1. Disable the SIR system. 2. Remove the upper and lower trim covers. Important: The abrasion sleeve located on the steering column wire harness assembly must be reinstalled. Make note of what connector is coming out of the abrasion sleeve for installation purposes. 3. Remove the wire harness assembly (1) from the wire harness strap (2). 4. Disconnect the turn signal and multifunction switch assembly connector from the SIR system coil connector. 5. Slide the 2 connectors (2) of the turn signal and multifunction switch assembly out of the bulkhead connector (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 11250 6. Remove the 2 pan head tapping screws (1) and (3) from the turn signal and multifunction switch assembly (2). 7. Remove the turn signal and multifunction switch assembly (2) from the steering column tilt head assembly. Installation Procedure 1. Install the turn signal and multifunction switch assembly (2) onto the steering column tilt head assembly. Notice: Refer to Fastener Notice in Service Precautions. Important: Be sure that the electrical contact of the turn signal and multifunction switch assembly (2) rests on the turn signal cancel cam assembly. 2. Screw the 2 pan head tapping screws (1) and (3) into the turn signal and multifunction assembly (2). ^ Tighten the top pan head tapping screw (1) to 3 Nm (27 in. lbs.). ^ Tighten the side pan head tapping screw (3) to 7 Nm (62 in. lbs.). 3. Slide the 2 connectors (2) of the turn signal and multifunction switch assembly into the bulkhead connector (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 11251 4. Connect the turn signal and multifunction switch assembly connector to the SIR coil connector. Important: The abrasion sleeve must be installed back onto the steering column wire harness assembly. The ignition lock cylinder case wires and connector must be hanging out of the middle of the abrasion sleeve. 5. Install the wire harness assembly (1) into the wire harness strap (2). 6. Install the upper and lower trim covers. 7. Enable the SIR system. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 11252 Turn Signal Switch: Service and Repair Turn Signal Cancel Cam and Steering Shaft Upper Bearing Spring Turn Signal Cancel Cam and Steering Shaft Upper Bearing Spring Replacement ^ Tools Required J 23653-SIR Steering Column Lock Plate Compressor - J 42137 Cam Orientation Plate Adapter Removal Procedure 1. Disconnect the battery negative cable. Caution: Refer to SIR Caution in Service Precautions. 2. Disable the SIR system. 3. Remove the inflator module. 4. Remove the steering wheel. 5. Remove the SIR coil from the steering column upper shaft. 6. Allow the SIR coil to hang. 7. Remove the wave washer (1) from the steering shaft (2). 8. Compress the shaft lock plate using J23653-SIR and J42137. 9. Remove the bearing retainer (1) from the steering shaft. 10. Remove J23653-S/R and J42137 from the steering shaft. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 11253 11. Remove the shaft lock shield (5) from the steering shaft. 12. Remove the turn signal cancel cam (4) from the steering shaft. 13. Remove the upper bearing spring (3) from the steering shaft. 14. Remove the upper bearing inner race seat (2) from the steering shaft. 15. Remove the inner race (1) from the steering shaft. Installation Procedure 1. Lubricate the inner race (1) with GM P/N 12345718 (Canadian P/N 10953516). 2. Install the inner race (1) onto the steering shaft. 3. Install the upper bearing inner race seat (2) onto the steering shaft. 4. Install the upper bearing spring (3) onto the steering shaft. 5. Lubricate the lower brass surface of the turn signal cancel cam (4) with GM P/N 12377900 (Canadian P/N 10953529). 6. Install the turn signal cancel cam (4) onto the steering shaft. 7. Install the shaft lock shield (5) onto the steering shaft. 8. Compress the shaft lock shield (2) using J 23653-SIR and J 42137. 9. Install the new bearing retainer (1) onto the steering shaft. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Service and Repair > Multifunction Switch Replacement > Page 11254 10. Firmly seat the bearing retainer (1) into the groove on the steering shaft. 11. Remove J 23653-SIR and J 42137from the steering shaft. 12. Install the wave washer (1) onto the steering shaft (2). 13. Install the SIR coil. 14. Install the steering wheel. 15. Install the inflator module. 16. Enable the SIR system. 17. Connect the battery negative cable. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > Customer Interest for Vanity Lamp: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Vanity Lamp: Customer Interest Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Bulletin No.: 06-08-42-002A Date: January 23, 2007 TECHNICAL Subject: Sunshade (Visor) Vanity Mirror Bulb Inoperative (Replace Vanity Mirror Bulb Only) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2005-2007 Cadillac STS 2001-2005 Chevrolet Impala, Monte Carlo 2001-2006 Chevrolet Silverado Crew Cab, Suburban, Tahoe 2001-2006 GMC Sierra Crew Cab, Yukon, Yukon XL 2004-2005 Pontiac Grand Prix 2006-2007 HUMMER H3 Supercede: This bulletin is being updated to add the 2007 model year. Please discard Corporate Bulletin Number 06-08-42-002 (Section 08 - Body & Accessories). Condition Some customers may comment that a sunshade (visor) vanity mirror bulb is inoperative. Cause This condition may be caused by an inoperative bulb. Correction Do NOT replace the entire sunshade (visor) assembly. Replace the sunshade (visor) vanity mirror bulb with P/N 9442395 if repairing one of the affected models covered for an inoperative vanity mirror bulb. Refer to Vanity Mirror Lamp Replacement in SI. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > Customer Interest for Vanity Lamp: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. > Page 11263 The vanity mirror bulb can be accessed by removing the lens. Place a flat-bladed tool in the notches and gently pry out the lens. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vanity Lamp: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Vanity Lamp: All Technical Service Bulletins Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. Bulletin No.: 06-08-42-002A Date: January 23, 2007 TECHNICAL Subject: Sunshade (Visor) Vanity Mirror Bulb Inoperative (Replace Vanity Mirror Bulb Only) Models: 2005-2007 Buick Allure (Canada Only), LaCrosse 2005-2007 Cadillac STS 2001-2005 Chevrolet Impala, Monte Carlo 2001-2006 Chevrolet Silverado Crew Cab, Suburban, Tahoe 2001-2006 GMC Sierra Crew Cab, Yukon, Yukon XL 2004-2005 Pontiac Grand Prix 2006-2007 HUMMER H3 Supercede: This bulletin is being updated to add the 2007 model year. Please discard Corporate Bulletin Number 06-08-42-002 (Section 08 - Body & Accessories). Condition Some customers may comment that a sunshade (visor) vanity mirror bulb is inoperative. Cause This condition may be caused by an inoperative bulb. Correction Do NOT replace the entire sunshade (visor) assembly. Replace the sunshade (visor) vanity mirror bulb with P/N 9442395 if repairing one of the affected models covered for an inoperative vanity mirror bulb. Refer to Vanity Mirror Lamp Replacement in SI. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vanity Lamp: > 06-08-42-002A > Jan > 07 > Interior Lighting - Sun Visor Vanity Mirror Lamp Inop. > Page 11269 The vanity mirror bulb can be accessed by removing the lens. Place a flat-bladed tool in the notches and gently pry out the lens. Parts Information Warranty Information For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Connector Views Vanity Lamp: Connector Views Vanity Mirror Lamp-Left Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Connector Views > Page 11272 Vanity Mirror Lamp-Right Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Page 11273 Vanity Lamp: Description and Operation VANITY LAMPS The inadvertent power relay provides battery positive voltage to each vanity mirror lamp. When you open the vanity mirror cover on the sunshade a switch closes, providing a ground circuit, and the vanity lamp illuminates. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Page 11274 Vanity Lamp: Service and Repair VANITY MIRROR LAMP BULB REPLACEMENT REMOVAL PROCEDURE 1. Lower the sunshade and open the illuminated mirror door. 2. Insert a small flat-bladed tool at the lower edge of the lamp lens. Carefully press down to remove the lens. 3. Remove the bulb. INSTALLATION PROCEDURE 1. Install the bulb. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Lighting and Horns > Vanity Lamp > Component Information > Diagrams > Page 11275 2. Align the upper lens tab to the opening. Insert the upper edge of the lens. 3. Insert a small flat-bladed tool at the lower edge of the lamp lens. Carefully press up to install the lens. 4. Close the illuminated mirror door and raise the sunshade. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: Customer Interest A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11285 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11286 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > Customer Interest for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11287 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information Heated Glass Element: All Technical Service Bulletins A/C - Window Defroster Contact/Tab Repair Information INFORMATION Bulletin No.: 03-08-48-006H Date: April 11, 2011 Subject: Repair Information for Reconnection of Rear Window Defroster Contact or Tab Models: 2000-2012 GM Passenger Cars and Trucks 2003-2009 HUMMER H2 2006-2010 HUMMER H3 2005-2009 Saab 9-7X 2007-2010 Opel GT 2007-2008 Daewoo G2X Equipped With Electric Rear Window Defroster - RPO C49 Supercede: This bulletin is being revised to add the 2012 model year. Please discard Corporate Bulletin Number 03-08-48-006G (Section 08 - Body and Accessories). Repair Suggestions Soldering Defroster Contact Tabs In many cases the terminal tab will still be in the connector when you examine the vehicle. For Chevrolet Tahoe, Suburban, GMC Yukon, and Cadillac Escalade vehicles (with moveable glass), always replace the defroster tab (GM P/N 25916031) and the defroster electrical power connector (P/N 12034110). For all other vehicles, reconnect the original defroster tab. In most applications it is preferable to create a new solder connection to reattach a separated rear defroster tab. If you take note of the steps below, it is possible to create a new solder joint that is equal to, or stronger than, the original. The generic procedure below is not very time intensive, but does include minor preparation work to create a good bonding surface. Be sure to follow each of the steps, as combined they will produce the strongest bond possible. Please consider the following before attempting the repair: - Soldering introduces significant heat to the glass window of the vehicle. When performing the re-connection of the tab, use only the heat required to do the job. Pre-heat the soldering iron and have the solder in your other hand, ready to go, the moment you have enough heat to melt the solder. - If it is winter, bring the vehicle into the service garage and remove any snow from the back window area. Allow time for the glass to warm to the temperature inside the building. Soldering creates a "hot spot" in the glass. DO NOT solder on cold glass. Caution Heating the glass excessively, or repeatedly without time to cool, may result in glass breakage. ALWAYS wear safety glasses when performing this repair! - You MUST use a silver-bearing solder to make the connection. DO NOT attempt this repair with conventional tin/lead alloy solders. Silver bearing solder will adhere to the electrical buss bar, making a strong and lasting repair. - Protect surfaces under the area to be soldered. It is very easy to drip solder when performing this repair. Placing a shop towel under the soldering area is sufficient protection. Soldering Procedure 1. It is imperative to remove and replace the rear defroster electrical power connector by crimping a new connector to the feed wire. The proper connector P/N 12034110 can be found in the Packard Electrical Assortment, Tray 18, Position 5. - Insert Delphi pick 12094430 to depress the locking tab on the terminal. - Insert Delphi pick 12094429 to release the secondary lock tab. Important DO NOT re-use the existing defroster tab on new-style full-size utility vehicles with moveable glass. 2. Connect the electrical connector to the defroster tab. Fully engage the connector. An improperly seated connector may cause excessive resistance and impede the proper operation of the defroster. Add a small bead of solder to mate the electrical connector tab to the defroster tab. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11293 3. Prepare the surface of the used defroster tab (not required for new tabs on new-style full-size utility models) and the defroster buss bar with fine grain (500 grit) sandpaper or Emery cloth. It is not necessary to remove all of the original solder, but it should be scuffed sufficiently so that no oxidation is present. The photo above shows a close up of a properly prepared surface. Tip You may want to mask the glass around the contact area with tape. This is easy to do and will allow you to safely prepare the contact surface without the risk of scratching the glass or the black painted shading. Important Most rear glass has a black painted masking around the edge of the glass. When cleaning up the connection surface, be very careful not to damage the surface of the black shading or the surface of the glass. 4. Wipe the newly prepared contact area with Kent Automotive* Acrysol(TM) (or equivalent) to remove any residual oil or dirt. Important Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11294 You MUST use a silver-bearing solder to make the solder joint. DO NOT attempt this repair with conventional tin/lead alloy solders. Most suppliers have this type of solder available and it is available nationally at Radio Shack(R)*. It is sold in several diameters and either are acceptable for this repair. 5. For this step, it is permitted that two technicians be used if required. Heat the new connector on the surface of the buss bar that is to be soldered. Long nose pliers are suggested to hold the electrical connector and the defroster tab in place. Keep the solder ready and begin flowing out the solder as soon as the melting temperature has been reached. Tip If a single technician is attempting this repair, it is beneficial to wrap one turn of the solder around the new contacts base. In this manner, as the melting point of the solder is reached, a layer is deposited on the bottom side of the contact. Important Try to align the new contact so that it is positioned with the same orientation as the original contact. 6. The above illustrates an ideal finished solder joint. Additional stray solder will not harm the performance of the bond; however, while it is unlikely that customers may refer to the appearance of the rear window defroster and its components as a positive styling feature of the vehicle interior, it is easy to elicit the opposite reaction due to a poor cosmetic application. *We believe this source and their products to be reliable. There may be additional manufacturers of such products/materials. General Motors does not endorse, indicate any preference for, or assume any responsibility for the products or material from this firm or for any such items that may be available from other sources. Parts Information Acrysol(TM) can be ordered directly from Kent Automotive at 1-800-654-6333 (in Canada, 1-800-563-1717). Radio Shack(R) products can be found nationally at retail locations, www.radioshack.com, or at 1-800-843-7422. All other parts can be ordered through GMSPO or SSPO. Warranty Information (excluding Saab U.S. Models) For vehicles repaired under warranty, use: Warranty Information (Saab U.S. Models) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Heated Glass Element: > 03-08-48-006H > Apr > 11 > A/C - Window Defroster Contact/Tab Repair Information > Page 11295 For vehicles repaired under warranty, use the table. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Locations > Left Side of Rear Window Left Side Of Rear Window Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Locations > Left Side of Rear Window > Page 11298 Right Lower Corner Of Rear Window Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Locations > Left Side of Rear Window > Page 11299 Top Center Of Windshield Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions Heated Glass Element: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11302 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11303 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11304 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11305 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11306 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11307 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11308 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11309 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11310 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11311 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11312 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11313 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11314 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11315 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11316 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11317 Heated Glass Element: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11318 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11319 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11320 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11321 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11322 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11323 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11324 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11325 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11326 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11327 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11328 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11329 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11330 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11331 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11332 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11333 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11334 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11335 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11336 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11337 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11338 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11339 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11340 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11341 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11342 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11343 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11344 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11345 Rear Window Defogger Grid Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram Information and Instructions > Page 11346 Heated Glass Element: Electrical Diagrams Defogger Diagram Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Page 11347 Heated Glass Element: Description and Operation REAR WINDOW DEFOGGER DESCRIPTION AND OPERATION REAR WINDOW DEFOGGER SYSTEM COMPONENTS The rear window defogger system consist of the following components: HVAC control module - Body control module (BCM) - REAR DEFOG relay - Rear window defogger grid REAR WINDOW DEFOGGER OPERATION Battery positive voltage is supplied to the REAR DEFOG relay switched input. With the engine running, the BCM supplies battery positive voltage to REAR DEFOG relay coil. When you depress the rear window defogger switch, the HVAC control module illuminates the rear window defogger indicator and grounds the control circuit of the REAR DEFOG relay. This energizes the REAR DEFOG relay and allows battery positive voltage from the relay switched input through the switch contacts and out the relay switched output to the REAR DEFOG circuit breaker to the rear window defogger grid. Ground for the rear window defogger is provided by G309. When you start the engine and press the rear window defogger switch for the first time, the defogger cycle lasts for 15 minutes. Further operation results in 7.5 minute defogger cycles. The defogger cycle resets to 15 minutes when you cycle the ignition to the OFF position and then back to the ON position. If battery voltage is low, the BCM will disable the rear window defogger by removing the battery positive voltage supplied to the REAR DEFOG relay coil. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview Heated Glass Element: Initial Inspection and Diagnostic Overview Diagnostic Starting Point - Heated Glass Element DIAGNOSTIC STARTING POINT - HEATED GLASS ELEMENTS For the inside rearview mirror with the automatic day-night feature, begin the diagnosis by reviewing the system Description and Operation. Reviewing the Description and Operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Heated Glass Element in order to identify the correct procedure for diagnosing the system and where the procedure is located. See: Symptom Related Diagnostic Procedures For the rear window defogger, begin the diagnosis with the Diagnostic System Check - Defogger. The Diagnostic System Check will provide the following information: - The identification of the control modules which command the system - The ability of the control modules to communicate through the serial data circuit - The identification of any stored diagnostic trouble codes (DTCs) and their status The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and where the procedure is located. Diagnostic System Check - Heated Glass Element DIAGNOSTIC SYSTEM CHECK - DEFOGGER TEST DESCRIPTION Steps 1 - 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11350 Steps 3 - 7 The number(s) below refer to the step number(s) on the diagnostic table. 2. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit. The specified procedure will determine the particular condition. 4. The symptom table will determine the correct diagnostic procedure to use. 5. The presence of DTCs which begin with "U" indicate some other module is not communicating. The specified procedure will compile all the available information before tests are performed. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11351 Heated Glass Element: Symptom Related Diagnostic Procedures A Symptoms SYMPTOMS - HEATED GLASS ELEMENT IMPORTANT: - For the inside rearview mirror with the automatic day-night feature, review the system operation in order to familiarize yourself with the system functions. Refer to Automatic Day-Night Mirror Description and Operation. - For the rear window defogger system, the following steps must be performed before using the symptom tables. 1. Perform the Diagnostic System Check - Defogger before using the symptom tables in order to verify that all of the following are true: - There are no DTCs set. - The control modules can communicate via the serial data link. See: Initial Inspection and Diagnostic Overview/Diagnostic System Check - Heated Glass Element 2. Review the rear window defogger system operation in order to familiarize yourself with the system functions. Refer to Rear Window Defogger Description and Operation. Visual/Physical Inspection - Inspect for aftermarket devices which could affect the operation of the rear window defogger or the automatic day-night feature of the inside rearview mirror. - Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom. Intermittent Faulty electrical connections or wiring may be the cause of intermittent conditions. Symptom List Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom: Defogger Inoperative - Rear Window - Defogger Grid Lines Diagnosis - Mirrors - Automatic Day-Night Inoperative Automatic Day/Night Mirror Inoperative - Mirrors MIRRORS - AUTOMATIC DAY-NIGHT INOPERATIVE DIAGNOSTIC AIDS The automatic day-night feature of the inside rearview mirror may not operate properly or become inoperative due to an intermittent short to battery voltage in the backup lighting system. TEST Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11352 Steps 1 - 2 Steps 3 - 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11353 Steps 8 - 12 Defogger Inoperative - Rear Window DEFOGGER INOPERATIVE - REAR WINDOW TEST DESCRIPTION Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11354 Steps 1 - 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11355 Steps 6 - 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11356 Steps 10 - 15 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11357 Steps 16 - 22 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11358 Steps 23 - 26 The number below refers to the step number on the diagnostic table. 5. Listen for an audible click when the REAR DEFOG relay operates. Command both the ON and OFF states of the REAR DEFOG relay. Repeat the commands as necessary. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 11359 Heated Glass Element: Component Tests and General Diagnostics DEFOGGER GRID LINES DIAGNOSIS 1. Start the engine. 2. Activate the rear window defogger system. 3. Connect a test lamp to a good ground. IMPORTANT: The test lamp brilliance will decrease proportionately to the increased resistance in the grid line as the probe is moved from the battery positive bus wire to the ground bus wire. The test lamp brilliance may vary from one window to another. 4. Move the test lamp probe from zone 5 to zone 1 along each grid line. - If the test lamp shows full brilliance at both ends of the grid lines. Inspect for an open or poor connection in the ground circuit of the rear window defogger grid. - If the test lamp goes out, test the grid line in at least 2 places (1,3) to eliminate the possibility of bridging the open (2) in the grid line. 5. If an open is discovered replace the rear window. Refer to Rear Window Replacement. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-44-005J > Jan > 10 > Audio - Poor Radio Reception/Static Interference Rear Defogger: Customer Interest Audio - Poor Radio Reception/Static Interference TECHNICAL Bulletin No.: 03-08-44-005J Date: January 20, 2010 Subject: Poor Radio Reception or Radio Static/Increased Interference with Rear Window Defogger On or Some Rear Window Defogger Grids May Be Inoperative (Diagnose and Repair Rear Window Defogger Heating Grid) Models: 1997-2005 Buick Century, LeSabre, Park Avenue, Regal 2005-2009 Buick Allure (Canada Only) 2005-2010 Buick LaCrosse 2006-2010 Buick Lucerne 1997-2001 Cadillac Catera 1997-2002 Cadillac Eldorado 1997-2004 Cadillac Seville 1997-2005 Cadillac DeVille 2003-2010 Cadillac CTS 2004-2010 Cadillac SRX 2005-2010 Cadillac STS 2006-2010 Cadillac DTS 2010 Chevrolet Camaro 1997-2004 Chevrolet Corvette 2000-2010 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 2004-2010 Chevrolet Aveo, Epica, Optra 2004-2007 Chevrolet Malibu (Classic Only) 1997-2003 Oldsmobile Aurora 1998-2002 Oldsmobile Intrigue 1999-2004 Oldsmobile Alero 1997-2006 Pontiac Grand Am 1997-2008 Pontiac Grand Prix 2004-2005 Pontiac GTO 2005-2010 Pontiac G6, G3/Wave (Canada Only) 2006-2009 Pontiac Solstice 2007-2009 Saturn SKY 2010 Saturn AURA Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 03-08-44-005I (Section 08 - Body and Accessories). Condition Some customers may comment that the radio has poor reception or radio static/increased interference when the rear window defogger is turned on. Also, some rear window defogger grids may be inoperative. Cause This condition may be due to microscopic cracks in the electrically heated grids of the rear window defogger. These cracks may cause electrical interference when the rear defogger is on and this could affect radio reception. Background The addition of vertical grid lines to the heated back window defogger circuits has made it difficult to detect broken defogger grid lines. In the past, it was a simple matter to use a voltmeter to check the continuity of each grid line in order to locate a non-functional line. New design back windows have two vertical grid lines that connect all of the horizontal grid lines together, thereby providing alternate routes for the electrical current to follow. This makes the old test method ineffective. Materials Required - Permatex Quick Grid, P/N 12346001 or equivalent Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-44-005J > Jan > 10 > Audio - Poor Radio Reception/Static Interference > Page 11368 - A small ball of fine steel wool Type 00 or equivalent - Optional - A strip of liquid crystal heat sensitive paper, 51 mm x 305 mm (2 in x 12 in) or similar size (Contact Edmund Scientific for part number CR30723-70 or go to www.scientificsonline.com), or - Optional - A portable infrared thermometer, GE-46819, available from Kent-Moore, or equivalent. Correction There are three distinct zones across the back window that must be checked. They are: - the driver's side outboard of the two vertical lines - the passenger side outboard of the two vertical lines - the central zone that falls between the two vertical lines To detect a broken grid line in any of the above three zones and to isolate the exact location of the break, perform the following: Caution - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. - Cover the rear shelf area to prevent damage to the interior trim material. 1. Start the engine and turn on the back window defogger. Important The first place to check should be the driver side segment 2 to 3 lines up from the bottom about 380-385 mm (15-15.2 in) from the buss bar. 2. Take the ball of fine steel wool and twist one end to a point. Move the point slowly across each grid line. Be sure to start at the far side of the zone and move it to the opposite side of the zone. When you bridge the grid line break with the steel wool, you will see a small spark. Repeat the test over the same area to be sure you have accurately located the break. Mark the exact location of the grid line break. Repeat this portion of the test for each grid line. If you do not see a spark at any point, it is possible that there are two breaks in the same line and zone. Close visual inspection using a magnifying glass may be the only way to locate breaks in this case. 3. The following are provided as a alternative way to detect a non-functional grid line. If available, use in addition to the steel wool. 1. Method using liquid crystal heat sensitive paper. Important The first part of the test must be completed quickly before the entire surface of the back window becomes warm. 1. From outside the vehicle, place the heat sensitive paper (dull surface in contact with the glass) against the top driver side grid line. Start the engine and turn on the back window defogger. A distinct color change will take place at each conductive grid line. Repeat for the bottom grid lines until they have all been checked in the driver side zone. 2. Repeat the process for the passenger side and center area zones. 3. If no color change is noted for a grid line, place a crayon or china marker check mark beside it. Mark each grid line in the zone where it is non-conductive and therefore not heating up. More than one broken grid line may be found. 2. Method using a portable infrared thermometer. 1. Start the engine and turn on the rear back window defogger. 2. From inside the vehicle, start at the top driver side grid line and slowly run the portable infrared thermometer vertically down the rear window contacting each grid line. You should be able to see a district variation in temperature readings. 3. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 4. Repeat the process for the passenger side and center area zones. 4. Use Permatex Quick Grid, P/N 12346001, or equivalent, to repair each broken grid line. Follow the manufacturer's instructions. 5. Wait 24 hours before turning the defogger on, or the repair can be fast cured using a heat gun, 260°C-371°C (500°F-700°F). Hold the heat gun within 25-51 mm (1-2 in) from the repair point for 2 to 3 minutes. 6. Recheck the grid line with the heat sensitive paper or a portable infrared thermometer to ensure that the line is now functional and that the repair was successful. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Customer Interest: > 03-08-44-005J > Jan > 10 > Audio - Poor Radio Reception/Static Interference > Page 11369 For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Defogger: > 03-08-44-005J > Jan > 10 > Audio - Poor Radio Reception/Static Interference Rear Defogger: All Technical Service Bulletins Audio - Poor Radio Reception/Static Interference TECHNICAL Bulletin No.: 03-08-44-005J Date: January 20, 2010 Subject: Poor Radio Reception or Radio Static/Increased Interference with Rear Window Defogger On or Some Rear Window Defogger Grids May Be Inoperative (Diagnose and Repair Rear Window Defogger Heating Grid) Models: 1997-2005 Buick Century, LeSabre, Park Avenue, Regal 2005-2009 Buick Allure (Canada Only) 2005-2010 Buick LaCrosse 2006-2010 Buick Lucerne 1997-2001 Cadillac Catera 1997-2002 Cadillac Eldorado 1997-2004 Cadillac Seville 1997-2005 Cadillac DeVille 2003-2010 Cadillac CTS 2004-2010 Cadillac SRX 2005-2010 Cadillac STS 2006-2010 Cadillac DTS 2010 Chevrolet Camaro 1997-2004 Chevrolet Corvette 2000-2010 Chevrolet Impala 2000-2007 Chevrolet Monte Carlo 2004-2010 Chevrolet Aveo, Epica, Optra 2004-2007 Chevrolet Malibu (Classic Only) 1997-2003 Oldsmobile Aurora 1998-2002 Oldsmobile Intrigue 1999-2004 Oldsmobile Alero 1997-2006 Pontiac Grand Am 1997-2008 Pontiac Grand Prix 2004-2005 Pontiac GTO 2005-2010 Pontiac G6, G3/Wave (Canada Only) 2006-2009 Pontiac Solstice 2007-2009 Saturn SKY 2010 Saturn AURA Supercede: This bulletin is being revised to add models. Please discard Corporate Bulletin Number 03-08-44-005I (Section 08 - Body and Accessories). Condition Some customers may comment that the radio has poor reception or radio static/increased interference when the rear window defogger is turned on. Also, some rear window defogger grids may be inoperative. Cause This condition may be due to microscopic cracks in the electrically heated grids of the rear window defogger. These cracks may cause electrical interference when the rear defogger is on and this could affect radio reception. Background The addition of vertical grid lines to the heated back window defogger circuits has made it difficult to detect broken defogger grid lines. In the past, it was a simple matter to use a voltmeter to check the continuity of each grid line in order to locate a non-functional line. New design back windows have two vertical grid lines that connect all of the horizontal grid lines together, thereby providing alternate routes for the electrical current to follow. This makes the old test method ineffective. Materials Required - Permatex Quick Grid, P/N 12346001 or equivalent Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Defogger: > 03-08-44-005J > Jan > 10 > Audio - Poor Radio Reception/Static Interference > Page 11375 - A small ball of fine steel wool Type 00 or equivalent - Optional - A strip of liquid crystal heat sensitive paper, 51 mm x 305 mm (2 in x 12 in) or similar size (Contact Edmund Scientific for part number CR30723-70 or go to www.scientificsonline.com), or - Optional - A portable infrared thermometer, GE-46819, available from Kent-Moore, or equivalent. Correction There are three distinct zones across the back window that must be checked. They are: - the driver's side outboard of the two vertical lines - the passenger side outboard of the two vertical lines - the central zone that falls between the two vertical lines To detect a broken grid line in any of the above three zones and to isolate the exact location of the break, perform the following: Caution - Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. - Cover the rear shelf area to prevent damage to the interior trim material. 1. Start the engine and turn on the back window defogger. Important The first place to check should be the driver side segment 2 to 3 lines up from the bottom about 380-385 mm (15-15.2 in) from the buss bar. 2. Take the ball of fine steel wool and twist one end to a point. Move the point slowly across each grid line. Be sure to start at the far side of the zone and move it to the opposite side of the zone. When you bridge the grid line break with the steel wool, you will see a small spark. Repeat the test over the same area to be sure you have accurately located the break. Mark the exact location of the grid line break. Repeat this portion of the test for each grid line. If you do not see a spark at any point, it is possible that there are two breaks in the same line and zone. Close visual inspection using a magnifying glass may be the only way to locate breaks in this case. 3. The following are provided as a alternative way to detect a non-functional grid line. If available, use in addition to the steel wool. 1. Method using liquid crystal heat sensitive paper. Important The first part of the test must be completed quickly before the entire surface of the back window becomes warm. 1. From outside the vehicle, place the heat sensitive paper (dull surface in contact with the glass) against the top driver side grid line. Start the engine and turn on the back window defogger. A distinct color change will take place at each conductive grid line. Repeat for the bottom grid lines until they have all been checked in the driver side zone. 2. Repeat the process for the passenger side and center area zones. 3. If no color change is noted for a grid line, place a crayon or china marker check mark beside it. Mark each grid line in the zone where it is non-conductive and therefore not heating up. More than one broken grid line may be found. 2. Method using a portable infrared thermometer. 1. Start the engine and turn on the rear back window defogger. 2. From inside the vehicle, start at the top driver side grid line and slowly run the portable infrared thermometer vertically down the rear window contacting each grid line. You should be able to see a district variation in temperature readings. 3. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 4. Repeat the process for the passenger side and center area zones. 4. Use Permatex Quick Grid, P/N 12346001, or equivalent, to repair each broken grid line. Follow the manufacturer's instructions. 5. Wait 24 hours before turning the defogger on, or the repair can be fast cured using a heat gun, 260°C-371°C (500°F-700°F). Hold the heat gun within 25-51 mm (1-2 in) from the repair point for 2 to 3 minutes. 6. Recheck the grid line with the heat sensitive paper or a portable infrared thermometer to ensure that the line is now functional and that the repair was successful. Warranty Information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Defogger: > 03-08-44-005J > Jan > 10 > Audio - Poor Radio Reception/Static Interference > Page 11376 For vehicles repaired under warranty, use the table above. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Defogger: > 04-08-48-001B > Jun > 05 > A/C - Broken Rear Window Defogger Grid Detection Rear Defogger: All Technical Service Bulletins A/C - Broken Rear Window Defogger Grid Detection Bulletin No.: 04-08-48-001B Date: June 28, 2005 INFORMATION Subject: Rear Window Defogger - Broken Heating Grid Detection Method Models: 2006 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add the 2006 model year and additional models. Please discard Corporate Bulletin Number 04-08-48-001A (Section 08 - Body and Accessories). The addition of vertical grid lines to the heated back window defogger circuits has made it difficult to detect broken defogger grid lines. In the past, it was a simple matter to use a voltmeter to check the continuity of each grid line in order to locate a non-functional line. Some new design back windows have two vertical grid lines that connect all of the horizontal grid lines together, thereby providing alternate routes for the electrical current to follow. This makes the old test method ineffective. If the vehicle does not have the vertical lines, the old (line-by-line) test methods can be used. Materials Required ^ Permatex(R) Quick Grid, GM P/N 12346001, or equivalent ^ A small ball of fine steel wool Type 00, or ^ Optional - A strip of liquid crystal heat sensitive paper, 51 mm x 305 mm (2 in x 12 in) or similar size (Contact Edmund Scientific at 800-728-6999 for part number CR30723-70 or go to www.scientificsonline.com), or ^ Optional-A portable infrared thermometer, GE-46819, available from Kent-Moore (1-800-345-2233), or equivalent. Correction There are three distinct zones across the back window that must be checked. They are: ^ the driver's side outboard of the two vertical lines ^ the passenger side outboard of the two vertical lines ^ the central zone that falls between the two vertical lines To detect a broken grid line in any of the above three zones and to isolate the exact location of the break, perform the following steps: Caution: ^ Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. ^ Cover the rear shelf area to prevent damage to the interior trim material. 1. Start the engine and turn on the back window defogger. 2. Take the ball of fine steel wool and twist one end to a point. Move the point slowly across each grid line. Be sure to start at the far side of the zone and move it to the opposite side of the zone. When you bridge the grid line break with the steel wool, you will see a small spark. Repeat the test over the same area to be sure you have accurately located the break. Mark the exact location of the grid line break. Repeat this portion of the test for each grid line. If you do not see a spark at any point, it is possible that there are two breaks in the same line and zone. Close visual inspection using a magnifying glass may be the only way to locate breaks in this case. 3. The following are provided as an alternative way to detect a non-functional grid line. If available, use in addition to the steel wool. 3.1. Method using liquid crystal heat sensitive paper: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Defogger: > 04-08-48-001B > Jun > 05 > A/C - Broken Rear Window Defogger Grid Detection > Page 11381 Important: The first part of the test must be completed quickly before the entire surface of the back window becomes warm. 3.1.1. From outside the vehicle, place the heat sensitive paper (dull surface in contact with the glass) against the top driver side grid line. Start the engine and turn on the back window defogger. A distinct color change will take place at each conductive grid line. Repeat for the bottom grid lines until they have all been checked in the driver side zone. 3.1.2. Repeat the process for the passenger side and center area zones. 3.1.3. If no color change is noted for a grid line, place a crayon or china marker check mark beside it. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2. Method using portable infrared thermometer: 3.2.1. Start the engine and turn on the rear back window defogger. 3.2.2. From inside the vehicle, start at the top driver side grid line and slowly run the portable infrared thermometer vertically down the rear window contacting each grid line. You should be able to see a district variation in temperature readings. 3.2.3. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2.4. Repeat the process for the passenger side and center area zones. 4. Use Permatex(R) Quick Grid, GM P/N 12346001, or equivalent, to repair each broken grid line. Follow the manufacturer's instructions. 5. Wait 24 hours before turning the defogger on, or the repair can be fast cured using a heat gun, 260°C - 371°C (500°F - 700°F). Hold the heat gun within 25 - 51 mm (1-2 in) from the repair point for 2 to 3 minutes. 6. Recheck the grid line with the heat sensitive paper or portable infrared thermometer to ensure that the line is now functional and that the repair was successful. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Defogger: > 04-08-48-001B > Jun > 05 > A/C - Broken Rear Window Defogger Grid Detection Rear Defogger: All Technical Service Bulletins A/C - Broken Rear Window Defogger Grid Detection Bulletin No.: 04-08-48-001B Date: June 28, 2005 INFORMATION Subject: Rear Window Defogger - Broken Heating Grid Detection Method Models: 2006 and Prior Passenger Cars and Light Duty Trucks (Including Saturn) 2003-2006 HUMMER H2 2006 HUMMER H3 Supercede: This bulletin is being revised to add the 2006 model year and additional models. Please discard Corporate Bulletin Number 04-08-48-001A (Section 08 - Body and Accessories). The addition of vertical grid lines to the heated back window defogger circuits has made it difficult to detect broken defogger grid lines. In the past, it was a simple matter to use a voltmeter to check the continuity of each grid line in order to locate a non-functional line. Some new design back windows have two vertical grid lines that connect all of the horizontal grid lines together, thereby providing alternate routes for the electrical current to follow. This makes the old test method ineffective. If the vehicle does not have the vertical lines, the old (line-by-line) test methods can be used. Materials Required ^ Permatex(R) Quick Grid, GM P/N 12346001, or equivalent ^ A small ball of fine steel wool Type 00, or ^ Optional - A strip of liquid crystal heat sensitive paper, 51 mm x 305 mm (2 in x 12 in) or similar size (Contact Edmund Scientific at 800-728-6999 for part number CR30723-70 or go to www.scientificsonline.com), or ^ Optional-A portable infrared thermometer, GE-46819, available from Kent-Moore (1-800-345-2233), or equivalent. Correction There are three distinct zones across the back window that must be checked. They are: ^ the driver's side outboard of the two vertical lines ^ the passenger side outboard of the two vertical lines ^ the central zone that falls between the two vertical lines To detect a broken grid line in any of the above three zones and to isolate the exact location of the break, perform the following steps: Caution: ^ Approved safety glasses and gloves should be worn when performing this procedure to reduce the chance of personal injury. ^ Cover the rear shelf area to prevent damage to the interior trim material. 1. Start the engine and turn on the back window defogger. 2. Take the ball of fine steel wool and twist one end to a point. Move the point slowly across each grid line. Be sure to start at the far side of the zone and move it to the opposite side of the zone. When you bridge the grid line break with the steel wool, you will see a small spark. Repeat the test over the same area to be sure you have accurately located the break. Mark the exact location of the grid line break. Repeat this portion of the test for each grid line. If you do not see a spark at any point, it is possible that there are two breaks in the same line and zone. Close visual inspection using a magnifying glass may be the only way to locate breaks in this case. 3. The following are provided as an alternative way to detect a non-functional grid line. If available, use in addition to the steel wool. 3.1. Method using liquid crystal heat sensitive paper: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > All Other Service Bulletins for Rear Defogger: > 04-08-48-001B > Jun > 05 > A/C - Broken Rear Window Defogger Grid Detection > Page 11387 Important: The first part of the test must be completed quickly before the entire surface of the back window becomes warm. 3.1.1. From outside the vehicle, place the heat sensitive paper (dull surface in contact with the glass) against the top driver side grid line. Start the engine and turn on the back window defogger. A distinct color change will take place at each conductive grid line. Repeat for the bottom grid lines until they have all been checked in the driver side zone. 3.1.2. Repeat the process for the passenger side and center area zones. 3.1.3. If no color change is noted for a grid line, place a crayon or china marker check mark beside it. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2. Method using portable infrared thermometer: 3.2.1. Start the engine and turn on the rear back window defogger. 3.2.2. From inside the vehicle, start at the top driver side grid line and slowly run the portable infrared thermometer vertically down the rear window contacting each grid line. You should be able to see a district variation in temperature readings. 3.2.3. Mark each grid line in the zone where it is non-conductive and, therefore, not heating up. More than one broken grid line may be found. 3.2.4. Repeat the process for the passenger side and center area zones. 4. Use Permatex(R) Quick Grid, GM P/N 12346001, or equivalent, to repair each broken grid line. Follow the manufacturer's instructions. 5. Wait 24 hours before turning the defogger on, or the repair can be fast cured using a heat gun, 260°C - 371°C (500°F - 700°F). Hold the heat gun within 25 - 51 mm (1-2 in) from the repair point for 2 to 3 minutes. 6. Recheck the grid line with the heat sensitive paper or portable infrared thermometer to ensure that the line is now functional and that the repair was successful. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions Rear Defogger: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11390 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11391 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11392 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11393 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11394 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11395 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11396 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11397 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11398 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11399 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11400 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11401 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11402 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11403 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11404 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11405 Rear Defogger: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11406 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11407 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11408 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11409 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11410 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11411 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11412 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11413 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11414 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11415 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11416 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11417 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11418 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11419 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11420 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11421 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11422 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11423 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11424 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11425 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11426 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11427 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11428 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11429 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11430 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11431 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Diagrams > Diagram Information and Instructions > Page 11432 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Interior - Power Window Switch Removal Precaution Power Window Switch: Technical Service Bulletins Interior - Power Window Switch Removal Precaution Bulletin No.: 04-08-64-007 Date: April 22, 2004 INFORMATION Subject: Proper Removal of Power Window Switch to Avoid Damage to Door Trim Pad or Power Window Switch - Remove Trim Pad First Models: 2004 Chevrolet Malibu Maxx To replace the left front door power window switch, the door panel must be removed. There is a retaining clip at the front of the switch and two retaining tabs on the side of the switch. The clip and tabs must be released from the back side of the door panel. Trying to pry the switch out of the door trim panel without releasing the tabs and clip from the back will result in damage to either the door trim panel, the switch bezel or both. may result. When removing the door trim panel, be careful not to pull on the wire to the trunk release switch, or damage to the switch. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Page 11438 Power Window Switch: Locations Front Of Driver Door Trim (Windows) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Page 11439 Front Door Trim-Typical Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Technical Service Bulletins > Page 11440 Front Of Right Rear Door Trim, Left Rear Similar Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11443 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11444 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11445 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11446 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11447 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11448 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11449 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11450 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11451 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11452 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11453 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11454 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11455 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11456 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11457 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11458 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11459 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11460 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11461 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11462 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11463 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11464 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11465 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11466 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11467 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11468 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11469 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11470 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11471 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11472 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11473 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11474 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11475 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11476 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11477 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11478 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11479 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11480 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11481 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11482 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11483 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11484 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11485 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11486 Power Window Switch: Connector Views Window Switch-Driver, C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11487 Window Switch-Driver, C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11488 Window Switch-Driver, C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11489 Window Switch-Front Passenger Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11490 Window Switch-Front Passenger Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11491 Window Switch-LR Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11492 Window Switch-LR Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11493 Window Switch-RR Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement Power Window Switch: Service and Repair Power Window Switch Replacement POWER WINDOW SWITCH REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Remove the front door pull cup screws (1) and pull cup from the front door trim panel. Armrest Pull Cup Replacement (Impala)Armrest Pull Cup Replacement (Monte Carlo). 2. Disconnect the electrical connectors from the front door power window control switch. 3. Remove the front door window control switch using a small, flat-bladed tool at the side of the switch. INSTALLATION PROCEDURE 1. Install the front door power window control switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connector to the power window control switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement > Page 11496 3. Install the front door pull cup and screws (1) to the front door trim panel. Armrest Pull Cup Replacement (Impala)Armrest Pull Cup Replacement (Monte Carlo). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement > Page 11497 Power Window Switch: Service and Repair Power Window Switch Replacement (Impala) Power Window Switch Replacement (Impala) Removal Procedure 1. Remove the front door pull cup screws (1) and pull cup from the front door trim panel. Armrest Pull Cup Replacement (Impala) Armrest Pull Cup Replacement (Monte Carlo). 2. Disconnect the electrical connectors from the front door power window control switch. 3. Remove the front door window control switch using a small, flat-bladed tool at the side of the switch. Installation Procedure 1. Install the front door power window control switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connector to the power window control switch. 3. Install the front door pull cup and screws (1) to the front door trim panel. Armrest Pull Cup Replacement (Impala) Armrest Pull Cup Replacement (Monte Carlo). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement > Page 11498 Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door POWER WINDOW SWITCH REPLACEMENT - REAR DOOR (IMPALA) REMOVAL PROCEDURE 1. Remove the rear door pull cup from the rear door trim panel. 2. Disconnect the electrical connectors from the power window control switch. 3. Remove the rear door window control switch from the pull cup using a small, flat-bladed tool at the side of the power window control switch to release the power window control switch retainer. 4. Remove the power window control switch from the rear door pull cup. INSTALLATION PROCEDURE 1. Install the rear door power window control switch to the rear door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the rear door power window control switch. 3. Install the rear door pull cup to the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement > Page 11499 Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door (Impala) Power Window Switch Replacement - Rear Door (Impala) Removal Procedure 1. Remove the rear door pull cup from the rear door trim panel. 2. Disconnect the electrical connectors from the power window control switch. 3. Remove the rear door window control switch from the pull cup using a small, flat-bladed tool at the side of the power window control switch to release the power window control switch retainer. 4. Remove the power window control switch from the rear door pull cup. Installation Procedure 1. Install the rear door power window control switch to the rear door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the rear door power window control switch. 3. Install the rear door pull cup to the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations Power Window Motor: Locations Inside Of Front Passenger Door, Driver Similar (Windows) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations > Page 11504 Inside Right Rear Door, Left Rear Similar (Windows) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions Power Window Motor: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11507 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11508 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11509 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11510 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11511 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11512 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11513 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11514 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11515 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11516 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11517 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11518 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11519 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11520 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11521 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11522 Power Window Motor: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11523 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11524 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11525 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11526 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11527 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11528 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11529 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11530 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11531 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11532 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11533 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11534 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11535 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11536 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11537 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11538 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11539 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11540 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11541 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11542 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11543 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11544 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11545 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11546 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11547 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11548 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11549 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11550 Power Window Motor: Connector Views Window Motor-Driver Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11551 Window Motor-Front Passenger Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11552 Window Motor-LR Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 11553 Window Motor-RR Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Technical Service Bulletins > Interior - Power Window Switch Removal Precaution Power Window Switch: Technical Service Bulletins Interior - Power Window Switch Removal Precaution Bulletin No.: 04-08-64-007 Date: April 22, 2004 INFORMATION Subject: Proper Removal of Power Window Switch to Avoid Damage to Door Trim Pad or Power Window Switch - Remove Trim Pad First Models: 2004 Chevrolet Malibu Maxx To replace the left front door power window switch, the door panel must be removed. There is a retaining clip at the front of the switch and two retaining tabs on the side of the switch. The clip and tabs must be released from the back side of the door panel. Trying to pry the switch out of the door trim panel without releasing the tabs and clip from the back will result in damage to either the door trim panel, the switch bezel or both. may result. When removing the door trim panel, be careful not to pull on the wire to the trunk release switch, or damage to the switch. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Technical Service Bulletins > Page 11558 Power Window Switch: Locations Front Of Driver Door Trim (Windows) Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Technical Service Bulletins > Page 11559 Front Door Trim-Typical Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Technical Service Bulletins > Page 11560 Front Of Right Rear Door Trim, Left Rear Similar Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Passenger Car Zoning PASSENGER CAR ZONING Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11563 Vehicle Zoning Table All grounds, in-line connectors, pass-through grommets, and splices have identifying numbers that correspond to where they are located in the vehicle. The following table explains the numbering system. Electrical Symbols Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11564 Electrical Symbols Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11565 Electrical Symbols Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11566 Electrical Symbols Part 3 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11567 Electrical Symbols Part 4 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11568 Electrical Symbols Part 5 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11569 Electrical Symbols Part 6 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11570 Electrical Symbols Part 7 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11571 Electrical Symbols Part 8 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11572 Electrical Symbols Part 9 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11573 Electrical Symbols Part 10 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11574 Electrical Symbols Part 11 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11575 Electrical Symbols Part 12 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11576 Electrical Symbols Part 13 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11577 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11578 Power Window Switch: Diagnostic Aids Basic Knowledge Required BASIC KNOWLEDGE REQUIRED Without a basic knowledge of electricity, it will be difficult to use the diagnostic procedures contained in the service manual. You should understand the basic theory of electricity, and know the meaning of voltage (volts), current (amps), and resistance (Ohms). You should also be able to read and understand a wiring diagram, as well as understand what happens in a circuit with an open or a shorted wire. Checking Aftermarket Accessories CHECKING AFTERMARKET ACCESSORIES Do not connect aftermarket accessories into the following circuits: CAUTION: Refer to SIR Caution in Service Precautions. - SIR circuits, all such circuits are indicated on circuit diagrams with the SIR symbol. NOTE: Refer to OBD II Symbol Description Notice in Service Precautions. - OBD II circuits, all such circuits are indicated on circuit diagrams with the OBD II symbol. Always check for aftermarket accessories (non-OEM) as the first step in diagnosing electrical problems. If the vehicle is so equipped, disconnect the system to verify that these add-on accessories are not the cause of the problems. Possible causes of vehicle problems related to aftermarket accessories include: Power feeds connected to points other than the battery - Antenna location - Transceiver wiring located too close to vehicle electronic modules or wiring - Poor shielding or poor connectors on antenna feed line - Check for recent service bulletins detailing installation guidelines for aftermarket accessories. Inducing Intermittent Fault Conditions INDUCING INTERMITTENT FAULT CONDITIONS In order to duplicate the customer's concern, it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related. Manipulation of a circuit can consist of a wide variety of actions, including: - Wiggling the harness - Disconnecting a connector and reconnecting - Stressing the mechanical connection of a connector - Pulling on the harness or wire in order to identify a separation/break inside the insulation - Relocating a harness or wires All these actions should be performed with some goal in mind. For instance, with a scan tool connected, wiggling the wires may uncover a faulty input to the control module. The snapshot option would be appropriate here. Refer to Scan Tool Snapshot Procedure. You may need to load the vehicle in order to duplicate the concern. This may require the use of weights, floorjacks, jackstands, frame machines, etc. In these cases you are attempting to duplicate the concern by manipulating the suspension or frame. This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection. A DMM set to Peak Min/Max mode and connected to the suspect circuit while testing can yield desirable results. Refer to Testing for Electrical Intermittents. Certainly, using the senses of sight, smell, and hearing while manipulating the circuit can provide good results as well. There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear. In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness. Such conditions would include high moisture conditions, along with exceptionally high or low temperatures. The following discusses how to expose the circuit to these kinds of conditions. Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt. By mixing table salt with water in sufficient quantities, you can enhance the conductive properties of water so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture. Mixing 0.35L (12 oz) of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent. Fill a normal spray bottle with this mixture. This mixture is sufficient to enhance the water's own conductivity. This may cause the circuit to fail more easily when sprayed. Once the mixture is completed, spray the suspect area liberally with the solution. Then, while monitoring either a scan tool or DMM, manipulate the harness as Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11579 discussed previously. High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related, you can simulate the condition using the J 25070. Using the heat gun, you can heat up the suspected area or component. Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition. The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature. If a heat gun is unavailable, consider this option to enhance your diagnosis. This option does not allow for the same control, however. Low Temperature Conditions Depending on the nature of the fault condition, placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect. If this is unsuccessful, use local cooling treatments such as ice or a venturi type nozzle (one that provides hot or cold air). This type of tool is capable of producing air stream temperatures down to -18°C (0°F) from one end and 71°C (160°F) from the other. This is ideally suited for localized cooling needs. Once the vehicle, component, or harness has been sufficiently cooled, manipulate the harness or components in an effort to duplicate the concern. Measuring Frequency MEASURING FREQUENCY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the frequency of a signal. IMPORTANT: Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range. 1. Apply power to the circuit. 2. Set the rotary dial of the DMM to the V (AC) position. 3. Connect the positive lead of the DMM to the circuit to be tested. 4. Connect the negative lead of the DMM to a good ground. 5. Press the Hz button on the DMM. 6. The DMM will display the frequency measured. Measuring Voltage MEASURING VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure measures the voltage at a selected point in a circuit. 1. Disconnect the electrical harness connector for the circuit being tested, if necessary. 2. Enable the circuit and/or system being tested. Use the following methods: - Turn ON the ignition, with the engine OFF. - Turn ON the engine. - Turn ON the circuit and/or system with a scan tool in Output Controls. - Turn ON the switch for the circuit and/or system being tested. 3. Select the V (AC) or V (DC) position on the DMM. 4. Connect the positive lead of the DMM to the point of the circuit to be tested. 5. Connect the negative lead of the DMM to a good ground. 6. The DMM displays the voltage measured at that point. Measuring Voltage Drop MEASURING VOLTAGE DROP NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure determines the difference in voltage potential between 2 points. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11580 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 point of the circuit to be tested. 3. Connect the negative lead of the DMM to the other point of the circuit. 4. Operate the circuit. 5. The DMM displays the difference in voltage between the 2 points. Probing Electrical Connectors PROBING ELECTRICAL CONNECTORS IMPORTANT: Always be sure to reinstall the connector position assurance (CPA) and terminal position assurance (TPA) when reconnecting connectors or replacing terminals. Frontprobe Disconnect the connector and probe the terminals from the mating side (front) of the connector. NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 43907 Connector Test Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11581 Refer to the shown table as a guide in selecting the correct test adapter for frontprobing connectors. Backprobe IMPORTANT: Backprobe connector terminals only when specifically required in diagnostic procedures. - Do not backprobe a sealed (Weather Pack(R)) connector, less than a 280 series Metri-Pack connector, a Micro-Pack connector, or a flat wire (dock and lock) connector. - Backprobing can be a source of damage to connector terminals. Use care in order to avoid deforming the terminal, either by forcing the test probe too far into the cavity or by using too large of a test probe. - After backprobing any connector, inspect for terminal damage. If terminal damage is suspected, test for proper terminal contact. Do not disconnect the connector and probe the terminals from the harness side (back) of the connector. Scan Tool Snapshot Procedure SCAN TOOL SNAPSHOT PROCEDURE Snapshot is a recording of what a control module on the vehicle was receiving for information while the snapshot is being made. A snapshot may be used to analyze the data during the time a vehicle condition is current. This allows you to concentrate on making the condition occur, rather than trying to view all the data in anticipation of the fault. The snapshot contains information around a trigger point that you have determined. Only a single data list may be recorded in each snapshot. The Scan Tool has the ability to store 2 snapshots. The ability to record 2 snapshots allows comparing hot versus cold and good versus bad vehicle scenarios. The snapshots are stored on a first-in, first-out basis. If a third snapshot is taken, the first snapshot stored in the memory will be lost. Snapshots can be 1 of 2 types: - Snapshot - taken from the Snapshot menu choice - Quick Snapshot - taken from the Data Display soft key choice, does not contain DTC information Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11582 When a snapshot is taken, it is recorded on the memory card and may contain as many as 1200 frames of information. Because the snapshot is recorded onto the memory card, snapshots are not lost if the Scan Tool is powered down. The snapshot replay screen has a plot soft key that can be of great value for intermittent diagnosis. The snapshot plot feature can help you to quickly determine if a sensor is outside of its expected values by plotting 3 parameters at a time. The data will be displayed both graphically and numerically showing the minimum and maximum values for all frames captured. This is helpful, especially if the fault occurs only once and does not set a DTC. Testing For a Short To Voltage TESTING FOR A SHORT TO VOLTAGE NOTE: Refer to Test Probe Notice in Service Precautions. The following procedure tests for a short to voltage in a circuit. 1. Set the rotary dial of the DMM to the V (DC) position. 2. Connect the positive lead of the DMM to 1 end of the circuit to be tested. 3. Connect the negative lead of the DMM to a good ground. 4. Turn ON the ignition and operate all accessories. 5. If the voltage measured is greater than 1 volt, there is a short to voltage in the circuit. Testing for Continuity TESTING FOR CONTINUITY NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures verify good continuity in a circuit. With a DMM 1. Set the rotary dial of the DMM to the. position. 2. Disconnect the power feed (i.e. fuse, control module) from the suspect circuit. 3. Disconnect the load. 4. Press the MIN MAX button on the DMM. 5. Connect one lead of the DMM to one end of the circuit to be tested. 6. Connect the other lead of the DMM to the other end of the circuit. 7. If the DMM displays low or no resistance and a tone is heard, the circuit has good continuity. With a Test Lamp IMPORTANT: Only use the test lamp procedure on low impedance power and ground circuits. 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to 1 end of the circuit to be tested. 4. Connect the other lead of the test lamp to battery positive voltage. 5. Connect the other end of the circuit to ground. 6. If the test lamp illuminates (full intensity), then the circuit has good continuity. Testing For Electrical Intermittents TESTING FOR ELECTRICAL INTERMITTENTS Perform the following procedures while wiggling the harness from side to side. Continue this at convenient points (about 6 inches apart) while watching the test equipment. - Testing for Short to Ground - Testing for Continuity - Testing for a Short to Voltage If the fault is not identified, perform the procedure below using the MIN MAX feature on the J 39200 DMM. This feature allows you to manipulate the circuit without having to watch the J 39200. The J 39200 will generate an audible tone when a change is detected. IMPORTANT: The J 39200 must be used in order to perform the following procedure since the J 39200 can monitor current, resistance or voltage while recording the minimum (MIN), and maximum (MAX) values measured. 1. Connect the J 39200 to both sides of a suspected connector (still connected), or from one end of a suspected circuit to the other. Refer to Troubleshooting with a Digital Multimeter for information on connecting the J 39200 to the circuit. 2. Set the rotary dial of the J 39200 to the V (AC) or V (DC) position. 3. Press the range button of the J 39200 in order to select the desired voltage range. 4. Press the MIN MAX button of the J 39200. The J 39200 displays 100 ms RECORD and emits an audible tone (beep). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11583 IMPORTANT: The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change. 5. Simulate the condition that is potentially causing the intermittent connection, either by wiggling the connections or the wiring, test driving, or performing other operations. Refer to Inducing Intermittent Fault Conditions. 6. Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded. 7. Press the MIN MAX button once in order to display the MAX value and note the value. 8. Press the MIN MAX button again in order to display the MIN value and note the value. 9. Determine the difference between the MIN and MAX values. - If the variation between the recorded MIN and MAX voltage values is 1 volt or greater an intermittent open or high resistance condition exists. Repair the condition as necessary. - If the variation between the recorded MIN and MAX voltage values is less than 1 volt an intermittent open or high resistance condition does not exist. Testing For Intermittent and Poor Connections TESTING FOR INTERMITTENT AND POOR CONNECTIONS Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items: - Wiring broken inside the insulation - Poor connection between the male and female terminal at a connector. - Poor terminal to wire connection-Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself and corrosion in the wire to terminal contact area, etc. - Wire insulation which is rubbed through-This causes an intermittent short as the bare area touches other wiring or parts of the vehicle. - Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required in order to verify the complaint. - Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions. - Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis. TESTING FOR PROPER TERMINAL CONTACT Tools Required J 42675 Flat-Wire Probe Adapter - J 38125-C Terminal Repair Kit It is important to test terminal contact at the component and any in-line connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation. Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit. Deformation is caused by probing the mating side of a connector terminal without the proper adapter, improperly joining the connector halves, or repeatedly separating and joining the connector halves. Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit. Round Wire Connectors Follow the procedure below to test terminal contact of Metri-Pack or 56 series terminals. Refer to the J 38125-C or the J 38125-4 Instruction Manual for terminal identification. Follow the procedure below in order to test terminal contact. 1. Separate the connector halves. 2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body. 3. Using an equivalent male terminal from the J 38125-C , test that the retention force is significantly different between a good terminal and a suspect terminal. Replace the female terminal in question. Flat Wire (Dock and Lock) Connectors There are no serviceable parts for flat wire (dock and lock) connectors on the harness side or the component side. Follow the procedure below in order to test terminal contact. 1. Remove the component in question. 2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well. 3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11584 contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation. 4. Insert the appropriate adapter from the J 42675 on the flat wire harness connector in order to test the circuit in question. Testing For Short to Ground TESTING FOR SHORT TO GROUND NOTE: Refer to Test Probe Notice in Service Precautions. The following procedures test for a short to ground in a circuit. With a DMM 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Set the rotary dial of the DMM to the. position. 4. Connect 1 lead of the DMM to 1 end of the circuit to be tested. 5. Connect the other lead of the DMM to a good ground. 6. If the DMM does NOT display infinite resistance (OL), there is a short to ground in the circuit. With a Test Lamp 1. Remove the power feed (i.e. fuse, control module) from the suspect circuit. 2. Disconnect the load. 3. Connect 1 lead of the test lamp to battery positive voltage. 4. Connect the other lead of the test lamp to 1 end of the circuit to be tested. 5. If the test lamp illuminates, there is a short to ground in the circuit. Fuse Powering Several Loads 1. Review the system schematic and locate the fuse that is open. 2. Open the first connector or switch leading from the fuse to each load. 3. Connect a DMM across the fuse terminals (be sure that the fuse is powered). - When the DMM displays voltage the short is in the wiring leading to the first connector or switch. - If the DMM does not display voltage refer to the next step. 4. Close each connector or switch until the DMM displays voltage in order to find which circuit is shorted. Troubleshooting With A Digital Multimeter TROUBLESHOOTING WITH A DIGITAL MULTIMETER NOTE: Refer to Test Probe Notice in Service Precautions. IMPORTANT: Circuits which include any solid state control modules, such as the PCM, should only be tested with a 10 megohm or higher impedance digital multimeter such as the J 39200. The J 39200 instruction manual is a good source of information and should be read thoroughly upon receipt of the DMM as well as kept on hand for future reference. A DMM should be used instead of a test lamp in order to test for voltage in high impedance circuits. While a test lamp shows whether voltage is present, a DMM indicates how much voltage is present. The ohmmeter function on a DMM shows how much resistance exists between 2 points along a circuit. Low resistance in a circuit means good continuity. IMPORTANT: Disconnect the power feed from the suspect circuit when measuring resistance with a DMM. This prevents incorrect readings. DMMs apply such a small voltage to measure resistance that the presence of voltages can upset a resistance reading. Diodes and solid state components in a circuit can cause a DMM to display a false reading. To find out if a component is affecting a measurement take a reading once, then reverse the leads and take a second reading. If the readings differ the solid state component is affecting the measurement. Following are examples of the various methods of connecting the DMM to the circuit to be tested: - Backprobe both ends of the connector and either hold the leads in place while manipulating the connector or tape the leads to the harness for continuous monitoring while you perform other operations or test driving. Refer to Probing Electrical Connectors. - Disconnect the harness at both ends of the suspected circuit where it connects either to a component or to other harnesses. - If the system that is being diagnosed has a specified pinout or breakout box, it may be used in order to simplify connecting the DMM to the circuit or for testing multiple circuits quickly. Troubleshooting With A Test Lamp TROUBLESHOOTING WITH A TEST LAMP TOOLS REQUIRED Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11585 J 34142-B 12-Volt Unpowered Test Lamp NOTE: Refer to Test Probe Notice in Service Precautions. A test lamp can simply and quickly test a low impedance circuit for voltage. The J 34142-B is Micro-Pack compatible and comprised of a 12-volt light bulb with an attached pair of leads. To properly operate this tool use the following procedure. 1. Attach 1 lead to ground. 2. Touch the other lead to various points along the circuit where voltage should be present. 3. When the bulb illuminates, there is voltage at the point being tested. Using Connector Test Adapters USING CONNECTOR TEST ADAPTERS NOTE: Do not insert test equipment probes into any connector or fuse block terminal. The diameter of the test probes will deform most terminals. A deformed terminal can cause a poor connection, which can result in system failures. Always use the J 35616-B Connector Test Adapter Kit or the J 42675 Flat Wire Probe Adapter Kit in order to frontprobe terminals. Do not use paper clips or other substitutes as they can damage terminals and cause incorrect measurements. Using Fused Jumper Wires USING FUSED JUMPER WIRES TOOLS REQUIRED J 36169-A Fused Jumper Wire IMPORTANT: A fused jumper may not protect solid state components from being damaged. The J 36169-A includes small clamp connectors that provide adaptation to most connectors without damage. This fused jumper wire is supplied with a 20-A fuse which may not be suitable for some circuits. Do not use a fuse with a higher rating than the fuse that protects the circuit being tested. Connector Position Assurance Locks CONNECTOR POSITION ASSURANCE LOCKS The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR mating terminals. Terminal Position Assurance Locks TERMINAL POSITION ASSURANCE LOCKS The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Push to Seat Connectors PUSH TO SEAT CONNECTORS TERMINAL REMOVAL Follow the steps below in order to repair push to seat connectors. 1. Remove the terminal position assurance (TPA) device, the connector position assurance (CPA) device, and/or the secondary lock. 2. Separate the connector halves (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11586 3. Use the proper pick or removal tool (1) in order to release the terminal. 4. Gently pull the cable and the terminal (2) out of the back of the connector. 5. Re-form the locking device if you are going to reuse the terminal (1). 6. To repair the terminal, refer to Terminal Repair. TERMINAL REPAIR 1. Slip the cable seal away from the terminal. 2. Cut the wire as close to the terminal as possible. 3. Slip a new cable seal onto the wire. 4. Strip 5 mm (3/16 in) of insulation from the wire. 5. Crimp a new terminal to the wire. 6. Solder the crimp with rosin core solder. 7. Slide the cable seal toward the terminal. 8. Crimp the cable seal and the insulation. 9. If the connector is outside of the passenger compartment, apply grease to the connector. REINSTALLING TERMINAL 1. In order to reuse a terminal or lead assembly. Refer to Diagnostic Aids for Circuit Testing and Wiring Repair procedures. 2. Ensure that the cable seal is kept on the terminal side of the splice. 3. Insert the lead from the back until it catches. 4. Install the TPA, CPA and/or the secondary locks. Pull to Seat Connectors PULL TO SEAT CONNECTORS TERMINAL REMOVAL If the terminal is visibly damaged or is suspected of having a faulty connection, the terminal should be replaced. Follow the steps below in order to repair pull-to-seat connectors: Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11587 1. Remove the connector position assurance (CPA) device and/or the secondary lock. 2. Disconnect the connector from the component or separate the connectors for in-line connectors. 3. Remove the terminal position assurance (TPA) device. 4. Insert the proper pick or removal tool into the front of the connector body. IMPORTANT: On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one. If the terminal wire does not have a large enough service loop for removal, cut the wire 5 cm (2 in) behind the connector before removal. 5. Grasp the wire at the back of the connector body and gently push the terminal (1) out the front of the connector body (3). TERMINAL REPAIR 1. If the wire needed to be cut in order to remove the terminal, gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in order to crimp on a new terminal. If the wire was not cut, cut the existing wire as close to the old terminal as possible. 2. Strip 5 mm (3/16 in) of insulation from the wire. 3. Crimp a new terminal to the wire. 4. Solder the crimp with rosin core solder. TERMINAL INSTALLATION 1. Align the terminal and pull the wire from the back of the connector in order to seat the terminal. 2. If necessary, cut the new wire to proper length and splice with existing circuit. Refer to Splicing Copper Wire Using Splice Sleeves. 3. If the connector is outside of the passenger compartment, apply dielectric grease to the connector. 4. Install the TPA, CPA and/or the secondary locks. Weather Pack Connectors WEATHER PACK CONNECTORS The following is the proper procedure for the repair of Weather Pack(R) Connectors. 1. Separate the connector halves (1). 2. Open the secondary lock. A secondary lock aids in terminal retention and is usually molded to the connector (1). 3. Grasp the wire and push the terminal to the forward most position. Hold the wire in this position. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11588 4. Insert the Weather Pack(R) terminal removal tool into the front (mating end) of the connector cavity until it rests on the cavity shoulder (1). 5. Gently pull on the wire to remove the terminal through the back of the connector (2). IMPORTANT: Never use force to remove a terminal from a connector. 6. Inspect the terminal and connector for damage. Repair as necessary. Refer to Repairing Connector Terminals. 7. Reform the lock tang (2) and reset terminal in connector body. 8. Close secondary locks and join connector halves. 9. Verify that circuit is complete and working satisfactorily. 10. Perform system check. Micro-Pack 100W Connectors MICRO-PACK 100W CONNECTORS TERMINAL REMOVAL PROCEDURE 1. Disconnect the connector from the component or separate the connector halves for in-line connectors. 2. Locate the nose piece locking tabs that are positioned on the side of the connector nose piece. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11589 3. Use a small flat-bladed tool to push in one of the locking tabs while gently pushing on the same side of the nose piece. 4. Repeat the procedure for the other locking tab and remove the nose piece. 5. Remove the wire dress cover. The following is a general procedure for wire dress cover removal. Use this procedure as a guide, some dress cover removal procedures may vary. 6. Use fingers to squeeze the 2 locking legs of the cover. 7. Apply pressure and gently rock the cover until one locking leg is unseated. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11590 8. Continue to apply pressure and rock the cover until the second locking leg is unseated. Repeat procedure for the other side of the dress cover and remove the cover. 9. Use J 38125-12A tool to gently lift the terminal retaining tab while gently pulling the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. If the terminal is severely bent or damaged, push the wire out of the front of the connector instead of pulling it through. This will prevent damage to the internal seals of the connector. Once the terminal is pushed out of the connector, cut the wire as close to the terminal as possible and pull the wire through the connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly kit available through Saturn Service Parts. 1. Slide the new terminal into the correct cavity at the back of the connector. 2. Push the terminal into the connector until it locks into place. The new terminal should be even with the other terminals. Insure that the terminal is locked in place by gently pulling on the wire. 3. Replace the nose piece. 4. Replace the dress cover. Micro. 64 Connectors MICRO.64 CONNECTORS TOOLS REQUIRED J 44020Terminal Repair Kit TERMINAL REMOVAL PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11591 1. Locate the lever lock on the wire dress cover. While pressing the lock, pull the lever over and past the lock. 2. Disconnect the connector from the component. 3. Locate the 2-wire dress cover locking tabs that are opposite the wire end of the connector. Use a small flat-bladed tool to unlock the dress cover. 4. Once the front 2 locks are unlocked, lift the back 2 locks that are on the wire side of the connector. 5. If the connector has a nose piece, use a small flat-bladed tool to remove the nose piece by inserting the blade into the slot on the front of the connector and prying up on the nose piece. IMPORTANT: Always use care when removing a TPA in order to avoid damaging it. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11592 6. Remove the TPA by inserting a small flat-blade tool into the small slot on the TPA and pushing down until the TPA comes out of the connector. Gently pry the TPA out of the connector. 7. Insert the J 44020-4 (GM P/N 15314260) tool into the 2 triangular cavities on each side of the terminal at the front of the connector. 8. While holding the removal tool in place, gently pull the wire out of the back of the connector. Always remember never use force when pulling a terminal out of a connector. TERMINAL REPAIR PROCEDURE Use the appropriate wire assembly repair kits available through Saturn Service Parts. Repairing Connector Terminals REPAIRING CONNECTOR TERMINALS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11593 TOOLS REQUIRED J 38125-C Terminal Repair Kit Use the following repair procedures in order to repair the following: Push to Seat terminals - Pull to Seat terminals - Weather Pack(R) terminals Some terminals do not require all of the steps shown. Skip the steps that do not apply for your immediate terminal repair. The J 38125-C contains further information. 1. Cut off the terminal between the core and the insulation crimp. Minimize any wire loss. For Weather Pack(R) terminals, remove the seal. 2. Apply the correct seal per gage size of the wire. For Weather Pack(R) terminals, slide the seal back along the wire in order to enable insulation removal. 3. Remove the insulation. 4. For Weather Pack(R) terminals only, align the seal with the end of the cable insulation. 5. Position the strip in the terminal. For Weather Pack(R) terminals, position the strip and seal in the terminal. 6. Hand crimp the core wings. 7. Hand crimp the insulation wings. For Weather Pack(R) terminals, hand crimp the insulation wings around the seal and the cable. 8. Solder all of the hand crimp terminals excepting Micro-Pack 100 World terminals. Soldering Micro-Pack 100 World terminals may damage the terminal. Circuit Protection - Circuit Breakers CIRCUIT PROTECTION - CIRCUIT BREAKERS A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity. If there is a short or other type of overload condition in the circuit, the excessive current will open the circuit between the circuit breaker terminals. Two types of circuit breakers are used. Circuit Breaker: This type opens when excessive current passes through it for a period of time. It closes again after a few seconds, and if the cause of the high current is still present, it will open again. The circuit breaker will continue to cycle open and closed until the condition causing the high current is removed. Positive Temperature Coefficient (PTC) Circuit Breaker: This type greatly increases its resistance when excessive current passes through it. The excessive current heats the PTC device, as the device heats its resistance increases. Eventually the resistance gets so high that the circuit is effectively open. Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened, by removing the voltage from its terminals. Once the voltage is removed the circuit breaker will re-close within a second or 2. Circuit Protection - Fuses CIRCUIT PROTECTION - FUSES Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11594 Fuse Types The fuse is the most common method of an automotive wiring circuit protection. Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit. Fuses are an one time protection device and must be replaced each time the circuit is overloaded. To determine if a fuse is open, remove the suspected fuse and examine the element in the fuse for an open (break). If not broken, also check for continuity using a DMM or a continuity tester. If the element is open or continuity is suspect, replace the fuse with one of equal current rating. Circuit Protection - Fusible Links CIRCUIT PROTECTION - FUSIBLE LINKS Fusible link is wire designed to melt and break continuity when excessive current is applied. It is often located between or near the battery and starter or electrical center. Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken. If broken, it must be replaced with fusible link of the same gage size. Repairing a Fusible Link IMPORTANT: Fusible links cut longer than 225 mm (approximately 9 in) will not provide sufficient overload protection. Refer to Splicing Copper Wire Using Splice Clips. Flat Wire Repairs FLAT WIRE REPAIRS NOTE: The flat wire within the flex wiring harness is not serviceable. If an open or short exists within the flex wiring harness the complete harness must be replaced. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11595 Heated Oxygen Sensor (HO2S) Wiring Repairs HEATED OXYGEN SENSOR (HO2S) WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit NOTE: Do not solder repairs under any circumstances as this could result in the air reference being obstructed. If the heated oxygen sensor pigtail wiring, connector, or terminal is damaged the entire oxygen sensor assembly must be replaced. Do not attempt to repair the wiring, connector, or terminals. In order for the sensor to function properly it must have a clean air reference. This clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance. The following guidelines should be used when servicing the heated oxygen sensor: Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor, causing poor performance. Also, the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems. - Neither the sensor nor vehicle lead wires should be bent sharply or kinked. Sharp bends, kinks, etc., could block the reference air path through the lead wire. - Do not remove or defeat the oxygen sensor ground wire (where applicable). Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will also cause poor engine performance. - To prevent damage due to water intrusion, be sure that the peripheral seal remains intact on the vehicle harness connector. The engine harness may be repaired using the J 38125-C. Repairing Damaged Wire Insulation REPAIRING DAMAGED WIRE INSULATION Wire Size Conversion Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11596 If the conductive portion of the wire is not damaged, locate the problem and apply tape around the wire. If the damage is more extensive, replace the faulty segment of the wire. Refer to Splicing Copper Wire Using Splice Clips and follow the instruction to repair the wire. Sir/SRS Wiring Repairs SIR/SRS WIRING REPAIRS TOOLS REQUIRED J 38125-C Terminal Repair Kit The supplemental inflatable restraint (SIR) system/supplemental restraint system (SRS) requires special wiring repair procedures due to the sensitive nature of the circuitry. Follow the specific procedures and instructions when working with the SIR/SRS system wiring, and the wiring components (such as connectors and terminals). IMPORTANT: Do not use the terminals in the kit in order to replace damaged SIR/SRS system terminals unless specifically indicated by the terminal package. The tool kit J 38125-C contains the following items: - Special sealed splices - in order to repair the SIR/SRS system wiring - A wire stripping tool - A special crimping tool - A heat torch - An instruction manual The sealed splices have the following 2 critical features: - A special heat shrink sleeve environmentally seals the splice. The heat shrink sleeve contains a sealing adhesive inside. - A cross hatched (knurled) core crimp provides necessary contact integrity for the sensitive, low energy circuits. The J 38125-C also serves as a generic terminal repair kit. The kit contains the following items: - A large sampling of common electrical terminals - The correct tools in order to attach the terminals to the wires - The correct tools in order to remove the terminals from the connectors SIR/SRS Connector (Plastic Body and Terminal Metal Pin) Repair Use the connector repair assembly packs in order to repair the damaged SIR/SRS wire harness connectors and the terminals. Do not use the connector repair assembly pack in order to repair the pigtails. These kits include an instruction sheet and the sealed splices. Use the sealed splices in order to splice the new wires, connectors, and terminals to the harness. The splice crimping tool is color keyed in order to match the splices from the J 38125-C. You must use the splice crimping tool in order to apply these splices. The terminals in the SIR/SRS system are made of a special metal. This metal provides the necessary contact integrity for the sensitive, low energy circuits. These terminals are only available in the connector repair assembly packs. Do not substitute any other terminals for those in the assembly packs. If the individual terminals are damaged on the sensing and diagnostic module (SDM) harness connector, use 1 of the following 2 components in order to replace the SDM harness connector: The SDM harness connector pigtail assembly - The SDM harness connector replacement kit If the individual terminals are damaged on any other SIR/SRS connection, use the appropriate connector repair assembly pack in order to replace the entire connection. Replace the entire SIR/SRS wiring harness, if needed, in order to maintain Restraint Systems/SRS circuit integrity. SIR/SRS Wire Pigtail Repair IMPORTANT: Do not make wire, connector, or terminal repairs on components with wire pigtails. A wire pigtail is a wire or wires attached directly to the device (not by a connector). If a wiring pigtail is damaged, you must replace the entire component (with pigtail). The inflatable restraint steering wheel module coil is an example of a pigtail component. SIR/SRS Wire Repair Tools Required J 38125-C Terminal Repair Kit IMPORTANT: Refer to Wiring Repairs in order to determine the correct wire size for the circuit you are repairing. You must obtain this information in order to ensure circuit integrity. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11597 If any wire except the pigtail is damaged, repair the wire by splicing in a new section of wire of the same gage size (0.5 mm, 0.8 mm, 1.0 mm etc.). Use the sealed splices and splice crimping tool from the J 38125-C. Use the following wiring repair procedures in order to ensure the integrity of the sealed splice. IMPORTANT: You must perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. You must obtain a clean strip with all of the wire strands intact. 1. Open the harness by removing any tape: - Use a sewing seam ripper (available from sewing supply stores) in order to cut open the harness in order to avoid wire insulation damage. - Use the crimp and sealed splice sleeves on all types of insulation except tefzel and coaxial. - Do not use the crimp and sealed splice sleeve to form a splice with more than 2 wires coming together. 2. Cut as little wire off the harness as possible. You may need the extra length of wire in order to change the location of a splice. Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors. 3. Strip the insulation: - When adding a length of wire to the existing harness, use the same size wire as the original wire. - Perform one of the following items in order to find the correct wire size: Find the wire on the schematic and convert the metric size to the equivalent AWG size. - Use an AWG wire gage. - If you are unsure of the wire size, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation. - Strip approximately 7.5 mm (0.313 in) of insulation from each wire to be spliced. - Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands. - If the wire is damaged, repeat this procedure after removing the damaged section. 4. Select the proper sealed splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the splice sleeves and the crimp tool nests. 5. Use the Splice Crimp Tool from the J 38125-C in order to position the splice sleeve in the proper color nest of the Splice Crimp Tool. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11598 6. Place the splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the splice sleeve in the proper nest. 7. Insert the wire into the splice sleeve barrel until the wire hits the barrel stop. 8. Tightly close the handles of the crimp tool until the crimper handles open when released. The crimper handles will not open until you apply the proper amount of pressure to the splice sleeve. Repeat steps 4 and 5 for the opposite end of the splice. 9. Using the heat torch, apply heat to the crimped area of the barrel. 10. Gradually move the heat barrel to the open end of the tubing: - The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. SIR/SRS System Wire Splice Repair Apply a new splice (not sealed) from the J 38125-C if damage occurs to any of the original equipment splices (3 wires or more) in the SIR/SRS wiring harness. Carefully follow the instructions included in the kit for proper splice clip application. Connector Position Assurance (CPA) The connector position assurance (CPA) is a small plastic insert that fits through the locking tabs of all the SIR/SRS system electrical connectors. The CPA ensures that the connector halves cannot vibrate apart. You must have the CPA in place in order to ensure good contact between the SIR/SRS mating terminals. Terminal Position Assurance (TPA) The terminal position assurance (TPA) insert resembles the plastic combs used in the control module connectors. The TPA keeps the terminal securely seated in the connector body. Do not remove the TPA from the connector body unless you remove a terminal for replacement. Splicing Copper Wire Using Splice Clips SPLICING COPPER WIRE USING SPLICE CLIPS Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11599 IMPORTANT: When making a splice in an area that may be exposed to moisture use a crimp and seal splice sleeve instead of a Splice Clip. Refer to Splicing Copper Wire Using Splice Sleeves Tools Required J 38125-C Terminal Repair Kit 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original (except fusible link). - The wire's insulation must have the same or higher temperature rating. - Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: - Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced. 5. Select the proper clip to secure the splice. Follow the instructions in the J 38125-C in order to determine the proper clip size crimp tool and anvil. 6. Overlap the 2 stripped wire ends and hold them between thumb and forefinger. 7. Center the splice clip (2) over the stripped wires (1) and hold the clip in place. - Ensure that the wires extend beyond the clip in each direction. - Ensure that no insulation is caught under the clip. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11600 8. Center the crimp tool over the splice clip and wires. 9. Apply steady pressure until the crimp tool closes. Ensure that no strands of wire are cut. 10. Crimp the splice on each end (2). 11. Apply 60/40 rosin core solder to the opening in the back of the clip. Follow the manufacturer's instructions for the solder equipment. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11601 12. Tape the splice. Roll on enough tape in order to duplicate the thickness of the insulation on the existing wires. 13. Additional tape can be applied to the wire if the wire does not belong in a conduit or another harness covering. Use a winding motion in order to cover the first piece of tape. Splicing Copper Wire Using Splice Sleeves SPLICING COPPER WIRE USING SPLICE SLEEVES TOOLS REQUIRED J 38125-C Terminal Repair Kit IMPORTANT: Use only GM splice sleeves, other splice sleeves may not protect the splice from moisture or provide a good electrical connection. Use crimp and seal splice sleeves to form a one-to-one splice on all types of insulation except tefzel and coaxial to form a one-to-one splice. Use tefzel and coaxial where there is special requirements such as moisture sealing. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the desired wire. 2. Cut the wire. - Cut as little wire off the harness as possible. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11602 - Ensure that each splice is at least 40 mm (1.5 in) away from other splices, harness branches and connectors. This helps prevent moisture from bridging adjacent splices and causing damage. 3. Select the proper size and type of wire. - The wire must be of equal or greater size than the original. - The wire's insulation must have the same or higher temperature rating (4). Use general purpose insulation for areas that are not subject to high temperatures. - Use a cross-linked polyethylene insulated wire for areas where high temperatures are expected. IMPORTANT: Use cross-linked polyethylene wire to replace PVC, but do not replace cross-linked polyethylene with PVC. - Cross-linked polyethylene wire is not fuel resistant. Do not use to replace wire where there is the possibility of fuel contact. 4. Strip the insulation. - Select the correct size opening in the wire stripper or work down from the largest size. - Strip approximately 7.5 mm (5/16 in) of insulation from each wire to be spliced (1). 5. Select the proper splice sleeve (2) and the required crimp nest tool, refer to the Crimp and Seal Splice Table. 6. Place the nest tool in the J 38125-C crimp tool. 7. Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice. 8. Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest. 9. Insert the wires into the splice sleeve until the wire hits the barrel stop. The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice (3). 10. Close the handles of the J 38125-C until the crimper handles open when released. The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve. 11. Shrink the insulation around the splice. - Using the heat torch apply heat to the crimped area of the barrel. - Gradually move the heat barrel to the open end of the tubing. The tubing will shrink completely as the heat is moved along the insulation. - A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved. Splicing Inline Harness Diodes SPLICING INLINE HARNESS DIODES Many vehicle electrical systems use a diode to isolate circuits and protect the components from voltage spikes. When installing a new diode use the following procedure. 1. Open the harness. - If the harness is taped, remove the tape. - To avoid wiring insulation damage, use a sewing ripper in order to cut open the harness. - If the harness has a black plastic conduit, pull out the diode. 2. If the diode is taped to the harness, remove all of the tape. 3. Check and record the current flow direction and orientation of diode. 4. Remove the inoperative diode from the harness with a suitable soldering tool. IMPORTANT: If the diode is located next to a connector terminal remove the terminal(s) from the connector to prevent damage from the soldering tool. 5. Carefully strip away a section of insulation next to the old soldered portion of the wire(s). Do not remove any more than is needed to attach the new diode. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11603 6. Check current flow direction of the new diode, being sure to install the diode with correct bias. Reference the appropriate service manual wiring schematic to obtain the correct diode installation position. 7. Attach the new diode to the wire(s) using 60/40 rosin core solder. Before soldering attach some heat sinks (aluminum alligator clips) across the diode wire ends to protect the diode from excessive heat. Follow the manufacturer's instruction for the soldering equipment. 8. Reinstall terminal(s) into the connector body if previously removed. IMPORTANT: To prevent shorts to ground and water intrusion, completely cover all exposed wire and diode attachment points with tape. 9. Tape the diode to the harness or connector using electrical tape. Splicing Twisted or Shielded Cable SPLICING TWISTED OR SHIELDED CABLE Twisted/shielded cable is used in order to protect wiring from electrical noise. Two-conductor cable of this construction is used between the radio and the Delco-Bose(R) speaker/amplifier units and other applications where low level, sensitive signals must be carried. Follow the instructions below in order to repair the twisted/shielded cable. 1. Remove the outer jacket (1). Use care not to cut into the drain wire of the mylar tape. 2. Unwrap the tape. Do not remove the tape. Use the tape in order to rewrap the twisted conductors after the splice is made. 3. Prepare the splice. Untwist the conductors and follow the splicing instructions for copper wire. Staggering the splices by 65 mm is recommended. IMPORTANT: Apply the mylar tape with the aluminum side inward. This ensures good electrical contact with the drain wire. 4. Re-assemble the cable. - Rewrap the conductors with the mylar tape. - Use caution not to wrap the drain wire in the tape (1). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11604 - Follow the splicing instructions for copper wire and splice the drain wire. - Wrap the drain wire around the conductors and tape with mylar tape. 5. Tape over the entire cable. Use a winding motion when you apply the tape. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11605 Control Module References Part 1 Control Module References Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11606 Power Window Switch: Connector Views Window Switch-Driver, C1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11607 Window Switch-Driver, C2 Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11608 Window Switch-Driver, C2 Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11609 Window Switch-Front Passenger Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11610 Window Switch-Front Passenger Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11611 Window Switch-LR Part 1 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11612 Window Switch-LR Part 2 Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 11613 Window Switch-RR Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement Power Window Switch: Service and Repair Power Window Switch Replacement POWER WINDOW SWITCH REPLACEMENT (IMPALA) REMOVAL PROCEDURE 1. Remove the front door pull cup screws (1) and pull cup from the front door trim panel. Armrest Pull Cup Replacement (Impala)Armrest Pull Cup Replacement (Monte Carlo). 2. Disconnect the electrical connectors from the front door power window control switch. 3. Remove the front door window control switch using a small, flat-bladed tool at the side of the switch. INSTALLATION PROCEDURE 1. Install the front door power window control switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connector to the power window control switch. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement > Page 11616 3. Install the front door pull cup and screws (1) to the front door trim panel. Armrest Pull Cup Replacement (Impala)Armrest Pull Cup Replacement (Monte Carlo). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement > Page 11617 Power Window Switch: Service and Repair Power Window Switch Replacement (Impala) Power Window Switch Replacement (Impala) Removal Procedure 1. Remove the front door pull cup screws (1) and pull cup from the front door trim panel. Armrest Pull Cup Replacement (Impala) Armrest Pull Cup Replacement (Monte Carlo). 2. Disconnect the electrical connectors from the front door power window control switch. 3. Remove the front door window control switch using a small, flat-bladed tool at the side of the switch. Installation Procedure 1. Install the front door power window control switch to the front door pull cup pressing into place until fully seated. 2. Connect the electrical connector to the power window control switch. 3. Install the front door pull cup and screws (1) to the front door trim panel. Armrest Pull Cup Replacement (Impala) Armrest Pull Cup Replacement (Monte Carlo). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement > Page 11618 Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door POWER WINDOW SWITCH REPLACEMENT - REAR DOOR (IMPALA) REMOVAL PROCEDURE 1. Remove the rear door pull cup from the rear door trim panel. 2. Disconnect the electrical connectors from the power window control switch. 3. Remove the rear door window control switch from the pull cup using a small, flat-bladed tool at the side of the power window control switch to release the power window control switch retainer. 4. Remove the power window control switch from the rear door pull cup. INSTALLATION PROCEDURE 1. Install the rear door power window control switch to the rear door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the rear door power window control switch. 3. Install the rear door pull cup to the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Service and Repair > Power Window Switch Replacement > Page 11619 Power Window Switch: Service and Repair Power Window Switch Replacement - Rear Door (Impala) Power Window Switch Replacement - Rear Door (Impala) Removal Procedure 1. Remove the rear door pull cup from the rear door trim panel. 2. Disconnect the electrical connectors from the power window control switch. 3. Remove the rear door window control switch from the pull cup using a small, flat-bladed tool at the side of the power window control switch to release the power window control switch retainer. 4. Remove the power window control switch from the rear door pull cup. Installation Procedure 1. Install the rear door power window control switch to the rear door pull cup pressing into place until fully seated. 2. Connect the electrical connectors to the rear door power window control switch. 3. Install the rear door pull cup to the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Back Window Glass > Back Window Glass Moulding / Trim > Component Information > Service and Repair Back Window Glass Moulding / Trim: Service and Repair Rear Window Reveal Molding Replacement The rear window reveal molding is an applied molding design separate from the window. The rear window reveal molding is bonded to the rear window and may be bonded to the body. The rear window reveal molding may be replaced with rear window as an assembly, or the rear window reveal molding may be available as a separate service part. Refer to Urethane Adhesive Installation of Stationary Windows. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Corner Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Front Corner Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel Front Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Channel Retainer Replacement - Front Door (Impala) Removal Procedure 1. Remove the outside rearview mirror. 2. Pull down the front door window channel in order to gain access to the rivets. 3. Loosen the front door frame applique screws. Refer to Door Frame Applique Replacement - Front (Impala) Door Frame Applique Replacement Front (Monte Carlo). 4. Drill out the rivets. 5. Remove the front door window channel retainer from the front door. Installation Procedure 1. Position the front door window channel retainer to the front door. 2. Install the window channel retainer rivets. Notice: Refer to Fastener Notice in Service Precautions. 3. Tighten the front door frame applique screws. Refer to Door Frame Applique Replacement Front (Impala) Door Frame Applique Replacement Front (Monte Carlo). 4. Install the front door window channel in position. 5. Install the outside mirror. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 11634 Front Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Front Door Window (Impala) Removal Procedure 1. Remove the front door trim panel. 2. Remove the front door water deflector. 3. Remove the front door outer belt sealing strip. 4. Remove the front door window. 5. Remove the screws from the front door window channel. 6. Remove the front door window channel from the front door frame. 7. Remove the front door window channel from the front door. 8. Remove the screw from the front door rear window channel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 11635 9. Remove the front door rear window channel from the front door slot by pulling down to disengage the retainer clip. 10. Remove the front door rear window channel from the front door through the access hole in the inner front door panel. Installation Procedure 1. Position the front door window channel front channel into the front door. Notice: Refer to Fastener Notice in Service Precautions. 2. Install the front door window channel screws. Tighten the front door window channel screws to 10 N.m (89 lb in). 3. Install the front door window channel to the front door starting in the top corner working out in both directions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 11636 Firmly seat the front door window channel to the front door. 4. Install the front door rear window channel to the front door through the access hole in the inner front door panel. 5. Install the front door rear window channel to the front door slot by pushing up to engage the retainer clip. 6. Install the screw to the front door rear window channel. Tighten the front door weatherstrip channel screws to 10 N.m (89 lb in). 7. Install the front door window. 8. Inspect the front door window for proper operation. 9. Install the front door outer belt sealing strip. 10. Install the front door water deflector. 11. Install the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Front Door Window Glass > Front Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 11637 Front Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Front Door Window Belt Outer (Impala) Removal Procedure 1. Remove the outside rearview mirror. 2. Remove the rear screw from the front door outer belt sealing strip. 3. Remove the front door outer belt sealing strip. Installation Procedure 1. Position the front door outer belt sealing strip to the front door pinch-weld flange. 2. Install the front door outer belt sealing strip to the front door pinch-weld flange pressing into place until fully seated. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the screw to the rear of the front door outer belt sealing strip. Tighten the outer belt sealing strip screw to 2 N.m (18 lb in). 4. Install the outside rearview mirror. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Body - Vehicle Glass Distortion Information Quarter Window Glass: Technical Service Bulletins Body - Vehicle Glass Distortion Information INFORMATION Bulletin No.: 00-08-48-005D Date: September 10, 2010 Subject: Distortion in Outer Surface of Vehicle Glass Models: 2011 and Prior GM Passenger Cars and Trucks 2009 and Prior HUMMER H2 2010 and Prior HUMMER H3 2005-2009 Saab 9-7X 2010 and Prior Saturn Supercede: This bulletin is being revised to add model years. Please discard Corporate Bulletin Number 00-08-48-005C (Section 08 - Body and Accessories). Distortion in the outer surface of the windshield glass, door glass or backlite glass may appear after the vehicle has: - Accumulated some mileage. - Been frequently washed in automatic car washes, particularly "touchless" car washes. This distortion may look like a subtle orange peel pattern, or may look like a drip or sag etched into the surface of the glass. Some car wash solutions contain a buffered solution of hydrofluoric acid which is used to clean the glass. This should not cause a problem if used in the correct concentration. However, if not used correctly, hydrofluoric acid will attack the glass, and over time, will cause visual distortion in the outer surface of the glass which cannot be removed by scraping or polishing. If this condition is suspected, look at the area of the windshield under the wipers or below the belt seal on the side glass. The area of the glass below the wipers or belt seal will not be affected and what looks like a drip or sag may be apparent at the edge of the wiper or belt seal. You may also see a line on the glass where the wiper blade or the belt seal contacts the glass. Important The repair will require replacing the affected glass and is not a result of a defect in material or workmanship. Therefore, is not covered by New Vehicle Warranty. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Quarter Window Glass > Component Information > Technical Service Bulletins > Page 11642 Quarter Window Glass: Service and Repair Quarter Window Replacement (Impala) Tools Required * J 39032 Stationary Glass Removal Tool * Urethane Adhesive Kit GM P/N 12346392 or Equivalent * Isopropyl Alcohol or Equivalent * Cartridge-type Caulking Gun * Commercial-type Utility Knife * Razor Blade Scraper * Suction Cups * Plastic Paddle Removal Procedure Caution: If a window is cracked but still intact, crisscross the window with masking tape in order to reduce the risk of damage or personal injury. Important: Before cutting out a stationary window, apply a double layer of masking tape around the perimeter of the painted surfaces and inner trim of the window. 1. Remove the rear quarter upper trim. 2. Remove the rear quarter lower trim. Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: Keep the cutting edge of the tool against the window. Do this from inside the vehicle to protect the outer painted surface. 3. This will allow the urethane adhesive to be separated from the window. * Leave a base of urethane on the pinch-weld flange. * The only suitable lubrication is clear water. * Use J 39032 or equivalent in order to remove the window. * Remove the quarter modular window from the pinch-weld flange. Installation Procedure 1. Install a stationary window into the opening. 2. Install the rear quarter lower trim. 3. Install the rear quarter upper trim panel. 4. Remove the double layer of masking tape around the perimeter of the painted surfaces and the interior trim. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel Rear Door Window Glass Weatherstrip: Service and Repair Door Window Channel Window Channel Retainer Replacement - Rear Door (Impala) Removal Procedure 1. Partially remove the upper portion of the rear door frame appliques. Refer to Door Frame Applique Replacement - Rear (Impala Front) Door Frame Applique Replacement - Rear (Impala Rear). 2. Pull downwards on the rear door window channel to gain access to the rivets. 3. Drill out the rivets. 4. Remove the forward screw to the rear window channel retainer. 5. Remove the rear window channel retainer from the rear door. Installation Procedure 1. Position the rear window weatherstrip retainer. 2. Push downwards on the rear door window channel to gain access to the rivets holes. 3. Install weather strip retainer rivets. 4. Install the rear door frame applique. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 11648 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Weatherstrip Weatherstrip Replacement - Rear Door Window (Impala) Removal Procedure 1. Place the rear window in the full down position. 2. Remove the rear door trim panel. 3. Remove the outer belt sealing strip. 4. Remove the rear window channel from the door. Installation Procedure 1. Position the rear window channel to the rear door starting in the corner. Work outward in both directions. 2. Firmly seat the rear window channel to the rear door. 3. Inspect the rear door window for proper operation. 4. Install the outer belt sealing strip. 5. Install the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 11649 Rear Door Window Glass Weatherstrip: Service and Repair Door Window Sealing Strip Sealing Strip Replacement - Rear Door Window Belt Outer (Impala) Removal Procedure 1. Position the rear window all the way down. 2. Remove the rear door trim panel to have access to these screws. 3. Remove the rear door outer belt sealing strip screws. 4. Remove the rear window outer belt sealing strip by pulling the sealing strip from the rear door pinch-weld flange. Installation Procedure 1. Position the rear door outer belt sealing strip to the rear door pinch-weld flange. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Glass > Rear Door Window Glass > Rear Door Window Glass Weatherstrip > Component Information > Service and Repair > Door Window Channel > Page 11650 2. Install the rear door outer belt sealing strip to the pinch-weld flange, pressing into place until full seated. Notice: Refer to Fastener Notice in Service Precautions. 3. Install the rear door outer belt sealing strip screws. Tighten the rear door outer belt sealing strip screws to 2 N.m (18 lb in). 4. Install Rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Window Regulator Replacement - Front Door (Impala) Removal Procedure 1. Position the front door window with a 6.3 mm (1/4 in) space at the top. 2. Tape the window to the window frame. 3. Remove the front door trim panel. 4. Remove the front door water deflector. 5. Disconnect the front window from the front window regulator carrier plate. 6. Disconnect the electrical connector from the front window regulator motor. 7. Loosen the bolts on the front window regulator motor. 8. Loosen the top bolts and remove the lower bolts on the front window regulator rail. 9. Remove the front window regulator, lifting up and out from the key slots on the front door inner panel and through the rear access hole. Installation Procedure 1. Install the top window regulator bolts half way into the window regulator motor and the rail. 2. Position the front window regulator rail through the rear access hole first. 3. Position the front window regulator motor through the rear access hole. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair > Page 11655 4. Install the front window regulator bolts into the key slots. Tighten the front window regulator motor and the rail bolts to 10 N.m (89 lb in). 5. Remove the tape from the front window and position the front window to the front window regulator carrier plate. 6. Connect the front window to the front window regulator carrier plate. 7. Connect the electrical connector to the front window regulator motor. 8. Install the front door water deflector. 9. Install the front door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair Rear Door Window Regulator: Service and Repair Window Regulator Replacement - Rear Door (Impala) Removal Procedure 1. Position the front door window with a 6.3 mm (1/4 in) space at the top. 2. Tape the window to the window frame. 3. Remove the rear door trim panel. 4. Remove the rear door water deflector. 5. Disconnect the rear window from the rear window regulator carrier plate. 6. Disconnect the electrical connector from the rear window regulator motor. 7. Loosen the bolts on the rear window regulator motor. 8. Loosen the bolts on the rear window regulator rail. 9. Remove the rear window regulator, lifting up and out from the key slots on the rear door inner panel and through the rear access hole. Installation Procedure 1. Install the rear window regulator bolts half way into the rear window regulator motor and the rail. 2. Position the rear window regulator rail through the rear access hole first. 3. Position the rear window regulator motor through the rear access hole. Notice: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windows > Window Regulator > Rear Door Window Regulator > System Information > Service and Repair > Page 11659 4. Install the rear window regulator into the key slots. Tighten the rear window regulator motor and the rail bolts to 10 N.m (89 lb in). 5. Remove the tape from the rear window and position the rear window to the rear window regulator carrier plate. 6. Connect the rear window to the rear window regulator carrier plate. 7. Connect the electrical connector to the rear window regulator motor. 8. Install the rear door water deflector. 9. Install the rear door trim panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Procedures Windshield Moulding / Trim: Procedures Stationary Window Reveal Molding Repair Removal Procedure Caution: Refer to Glass and Sheet Metal Handling Caution in Service Precautions. Important: The window reveal molding fills the cavity between the body and window. If the reveal molding is stretched or damaged, it cannot be reused and it must be replaced. 1. Lift up on the loose area of the reveal molding. 2. Clean the top edge of the window surface and the reveal molding with a 50/50 mixture of isopropyl alcohol and water by volume on a dampened lint-free cloth. 3. If the reveal molding cannot be reused, refer to Stationary Window Reveal Molding Repair. Installation Procedure Caution: Refer to Window Retention Caution in Service Precautions. 1. Verify all primers and urethane adhesive are within expiration dates. Important: Use care when applying the prep, clear #1, to the window. This primer dries almost instantly, and may stain the viewing area of the window if not applied evenly. 2. Use a new dauber in order to apply glass prep, clear #1, to the channel area approximately 13 mm (1/2 in) to the upper edge of the window. 3. Wipe the glass primed area immediately with a clean lint-free cloth. 4. Shake the glass primer, black #2, for at least 1 minute. 5. Use a new dauber in order to apply glass primer, black #2, to the top edge of the window. 6. Apply a small bead of urethane adhesive (2) between the window (1) and the pinch-weld. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Procedures > Page 11665 7. Reinstall the window reveal molding. 1. Start from the loose area and hand-press the reveal molding into place over the edge of the window. 2. Run warm water over the reveal molding in order to speed the setup time of the urethane adhesive. 3. Tape should be applied in order to retain the reveal molding to the window. This will maintain a flush fit with the body. 4. The tape is to be removed after 6 hours. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Windows and Glass > Windshield > Windshield Moulding / Trim > Component Information > Service and Repair > Procedures > Page 11666 Windshield Moulding / Trim: Removal and Replacement Windshield Reveal Molding Replacement The windshield reveal molding is an applied molding design separate from the window. The reveal molding is bonded by to the windshield and may be bonded to the body. The reveal molding may be replaced with the windshield as an assembly, or the reveal molding may be available as a separate service part. Refer to Urethane Adhesive Installation of Stationary Windows. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Forward Of Windshield Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 11672 Windshield Wiper System Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 11673 Wiper Control Module: Service and Repair WIPER DRIVE SYSTEM MODULE REPLACEMENT TOOLS REQUIRED - J 39232 Wiper Transmission Separator - J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the air inlet grille panel. 2. Remove the wiper motor water deflector. 3. Using the J 39232 , disconnect the wiper transmission from the wiper motor crank arm to aid in the removal of the wiper drive system module. 4. Remove the wiper drive system module screws. 5. Disconnect the wiper motor electrical connector. 6. Remove the wiper drive system module from the vehicle. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 11674 1. Position the wiper drive system module to the vehicle. 2. Connect the wiper motor electrical connector. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the wiper drive system screws. Tighten Tighten the screws to 10 N.m (89 lb in). 4. Using the J 39529 , Install the wiper transmission to the wiper motor crank arm. 5. Install the wiper motor water deflector. 6. Install the air inlet grille panel. 7. Inspect the wipers for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Right Front Of Vehicle Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 11679 Windshield Washer Fluid Level Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 11680 Washer Fluid Level Switch: Service and Repair WASHER SOLVENT CONTAINER LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Drain the washer solvent from the washer solvent container. 2. Remove the right front fender liner. 3. Disconnect the washer solvent container level sensor electrical connector. 4. Using a small flat-bladed tool, remove the washer solvent level sensor from the washer solvent container. 5. Using a small flat-bladed tool, remove the seal from the washer solvent container. INSTALLATION PROCEDURE 1. Position the seal to the washer solvent container, pressing in until fully seated. 2. Position the washer solvent level sensor to the washer solvent container, pressing in until fully seated. 3. Connect the washer solvent level sensor electrical connector. 4. Install the right front fender liner. 5. Fill the washer solvent container with washer solvent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Windshield Washer Switch: Locations Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 11684 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Locations > Page 11688 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Right Front Of Vehicle Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 11692 Windshield Washer Fluid Level Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations > Page 11693 Washer Fluid Level Switch: Service and Repair WASHER SOLVENT CONTAINER LEVEL SENSOR REPLACEMENT REMOVAL PROCEDURE 1. Drain the washer solvent from the washer solvent container. 2. Remove the right front fender liner. 3. Disconnect the washer solvent container level sensor electrical connector. 4. Using a small flat-bladed tool, remove the washer solvent level sensor from the washer solvent container. 5. Using a small flat-bladed tool, remove the seal from the washer solvent container. INSTALLATION PROCEDURE 1. Position the seal to the washer solvent container, pressing in until fully seated. 2. Position the washer solvent level sensor to the washer solvent container, pressing in until fully seated. 3. Connect the washer solvent level sensor electrical connector. 4. Install the right front fender liner. 5. Fill the washer solvent container with washer solvent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair Windshield Washer Hose: Service and Repair HOSE REPLACEMENT - WINDSHIELD WASHER REMOVAL PROCEDURE 1. Open the hood. 2. Remove the right front fender liner. 3. Disconnect the washer hose from the washer pump. 4. Lower the Vehicle. 5. Disconnect the washer hose from the wiper arms. 6. Disconnect the washer hose from the air inlet grille panel. 7. Pull the washer pump hose out from along side the right front inner fender and into the engine compartment. 8. Remove the washer hose from the vehicle. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Hose > Component Information > Service and Repair > Page 11697 1. Position the washer hose to the vehicle. 2. Route the washer pump hose down along side the right front inner fender and into the front inner fender area. 3. Connect the washer hose to the air inlet grille panel. 4. Connect the washer hose to the wiper arms. 5. Raise the vehicle. 6. Connect the washer hose to the washer pump. 7. Install the right front fender liner. 8. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams Windshield Washer Fluid Pump Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Page 11701 Windshield Washer Pump: Service and Repair WASHER PUMP REPLACEMENT REMOVAL PROCEDURE 1. Open the hood. 2. Drain the washer solvent from the washer solvent container. 3. Remove the right front fender liner. 4. Disconnect the washer pump electrical connector. 5. Disconnect the washer pump hose. 6. Use a small flat-bladed tool to remove the washer pump from the washer solvent container. 7. Use a small flat-bladed tool to remove the seal from the washer solvent container. INSTALLATION PROCEDURE 1. Install the seal to the washer solvent container. 2. Install the washer pump to the washer solvent container. 3. Connect the washer pump electrical connector. 4. Connect the washer pump hose. 5. Install the right front fender liner. 6. Fill the washer solvent container with washer solvent. 7. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Washer Solvent Container Replacement Windshield Washer Reservoir: Service and Repair Washer Solvent Container Replacement WASHER SOLVENT CONTAINER REPLACEMENT REMOVAL PROCEDURE 1. Drain the washer solvent from the washer solvent container. 2. Remove the washer solvent container filler neck. 3. Remove the right headlamp assembly. 4. Remove the washer solvent container screws. 5. Remove the front fender liner. 6. Disconnect the washer pump hose. 7. Disconnect the washer pump electrical connector. 8. Disconnect the washer solvent level sensor electrical connector. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Washer Solvent Container Replacement > Page 11706 9. Remove the washer solvent container bracket screw. 10. Remove the washer solvent container from the right frame rail. INSTALLATION PROCEDURE 1. Position the washer solvent container to the right frame rail. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the washer solvent container bracket screw. Tighten Tighten the screw to 10 N.m (89 lb in). Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Washer Solvent Container Replacement > Page 11707 3. Connect the washer solvent level sensor electrical connector. 4. Connect the washer pump electrical connector. 5. Connect the washer pump hose. 6. Install the front fender liner. 7. Install the washer solvent container screws. Tighten Tighten the screws to 10 N.m (89 lb in). 8. Install the right headlamp assembly. 9. Install the washer solvent container filler neck. 10. Fill the washer solvent container with washer solvent. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information > Service and Repair > Washer Solvent Container Replacement > Page 11708 Windshield Washer Reservoir: Service and Repair Washer Solvent Container Filler Neck Replacement WASHER SOLVENT CONTAINER FILLER NECK REPLACEMENT REMOVAL PROCEDURE 1. Open the Hood. 2. Remove the washer solvent container filler neck push-in retainer. 3. Remove the washer solvent container filler neck from the washer solvent container. INSTALLATION PROCEDURE 1. Position the washer solvent container filler neck to the washer solvent container, pressing in until fully seated. 2. Install the washer solvent container filler neck push-in retainer. 3. Close the hood. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations Windshield Washer Switch: Locations Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Locations > Page 11712 Turn Signal/Multifunction Switch Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair Wiper Arm: Service and Repair WIPER ARM REPLACEMENT TOOLS REQUIRED J 39822 Wiper Arm Puller REMOVAL PROCEDURE 1. Turn the ignition ON. 2. Turn the wiper switch to DELAY. 3. Turn the ignition OFF when the wiper arms are paused at the bottom of the wipe pattern. 4. Disconnect the washer hose from the wiper arm. 5. Remove the wiper arm nut cover. 6. Remove the wiper arm nut. 7. Using the J 39822 , remove the wiper arm from the wiper transmission. INSTALLATION PROCEDURE 1. Install the wiper arms onto the wiper transmission. 2. Hold the measuring device at a 90 degree angle to the wiper blade while maintaining the following distances: - Right arm: 97-107 mm (3.82-4.21 in) from the end of the wiper arm to the air inlet screen. - Left arm: 125-147 mm (4.92-5.78 in) from the wiper blade tip to the air inlet screen. NOTE: Refer to Fastener Notice in Service Precautions. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair > Page 11716 3. Install the wiper arm nut. Tighten Tighten the nut to 30 N.m (22 lb ft). 4. Install the wiper arm nut cover. 5. Connect the washer hose to the wiper arm. 6. Operate the windshield wipers and inspect for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance Wiper Blade: Technical Service Bulletins Glass/Body - Windshield Wiper Performance INFORMATION Bulletin No.: 06-08-43-003C Date: February 21, 2011 Subject: Windshield Wiper Performance, Cleaning Instructions and Maintenance Models: 2012 and Prior GM Passenger Cars and Trucks (including Saturn) 2010 and Prior HUMMER H2, H3 2010 and Prior Isuzu Medium Duty Trucks 2005-2009 Saab 9-7X Supercede: This bulletin is being revised to add the 2011 and 2012 model year. Please discard Corporate Bulletin Number 06-08-43-003B (Section 08 - Body and Accessories). Wiper Concerns Most concerns about windshield wiper performance are the result of dirty wiper blades, damaged wiper blades, or worn out blades that are continuing to be used beyond their useful life. Depending on environmental conditions, wiper blades can have dramatic differences in lifespan. Here are some tips and guidelines to maximize wiper performance to avoid damage to the blades, and to avoid unnecessary replacements. Many wiper blades are being replaced under warranty with reviews showing there is nothing wrong with the returned blades other than a build-up of dirt. Additionally, advise the customer to review the information in their Owner Manual. Inspection and Cleaning Scheduled Maintenance - Inspect your wipers rubber blades every 4-6 months or 12,000 km (7,500 mi) for wear, cracking or contamination. - Clean the windshield and the rubber wiper blades (using the procedure below) if the blades are not clearing the glass satisfactorily. If this does not correct the problem, then replace the rubber elements. Cleaning Procedure Important Avoid getting windshield washer fluid on your hands. Wear rubber gloves or avoid direct contact with washer fluid. Important Do not use gasoline, kerosene, or petroleum based products to clean wiper blades. - Clean the rubber blades using a lint free cloth or paper towel soaked with windshield washer fluid or a mild detergent. You should see significant amounts of dirt being removed on the cloth. - Be sure to wash the windshield thoroughly when you clean the blades. Bugs, road grime, sap and a buildup of car wash/wax treatments may additionally cause wiper streaking. Tip For a larger scale buildup on the windshield, use a non-abrasive cleaner such as Bon-Ami* (www.faultless.com) cleanser with a wet sponge, being sure to use plenty of water to avoid scratching the glass. Flush the surface and body panels completely. Tip For day-to-day exterior glass cleaning and to maintain a streak free appearance, suggest Vehicle Care Glass Cleaner, P/N 88862560 (in Canada, 992727). This product is an easy to use foaming cleaner that quickly removes dirt and grime from glass surfaces. Tip Interior glass should be cleaned with plain, clean water to eliminate any film or haze on the window and help prevent fogging, a major customer dissatisfier. Refer to Corporate Bulletin Number 03-00-89-006D for more information. The New Vehicle Pre-Delivery Inspection form also recommends using plain water to clean interior glass. *"We believe this material to be reliable. There may be additional manufacturers of such material. General Motors does not endorse, indicate any preference for or assume any responsibility for the products or equipment from these firms or any such items which may be available from other sources. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service Bulletins > Glass/Body - Windshield Wiper Performance > Page 11721 Avoiding Wiper Damage The following are major contributors to wiper damage. Some of these you can control and others are environmental concerns. - Extremely dusty areas (such as driving on dirt roads) may cause the wipers rubber edge to wear quickly and unevenly. - Sand and salt used on roads for increasing winter traction and ice control will cause the wiper blades to wear quicker. Areas with significant snowfall require more frequent blade replacements. - Heat and time may cause the rubber blades to take a "permanent set" resulting in the rubber not flexing and turning over uniformly. This condition may result in streaking and/or unwiped areas. - Rubber blades are easily cut or torn when using ice scrapers. Likewise pulling blades up off a frozen windshield can tear the rubber. Exercise caution when clearing ice and snow. - Using your wipers to "wear through" frost and ice, instead of allowing the defrosters to melt the ice, can dull, nick or tear the rubber blades. - Banging wipers on the glass to remove ice and snow may cause the blade to bend, dislodging the rubber and causing potential scratching of the windshield. - Ice can form in the pin joints of the wipers, which can cause streaking and unwiped areas. To remove ice from pin joints, compress the blade and rubber edge with your hand to loosen the frozen joints. Consider using Winter Blades that have a rubber cover to avoid this condition. Note GM does not recommend the use of any spray on/wipe on windshield treatments or washer fluid additives. The variation in friction that results on the glass from the use of these products causes wipers to chatter and have premature wear. Disclaimer Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement Wiper Blade: Service and Repair Wiper Arm Blade Replacement WIPER ARM BLADE REPLACEMENT REMOVAL PROCEDURE 1. Turn the ignition ON. 2. Turn the wiper switch to the DELAY position. 3. Turn the ignition OFF when the windshield wipers are in the midwipe position. 4. Press the wiper blade clip button in to release the wiper blade from the inside radius of the wiper arm. 5. Remove the wiper arm out through the opening in the wiper blade. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 11724 1. Install the hook of the wiper arm through the opening in the wiper blade. 2. Position the wiper blade pivot in the inside radius of the wiper arm hook. 3. Press the wiper blade pivot into the wiper arm hook until the pivot locks into the hook. 4. Operate the windshield wipers and inspect for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 11725 Wiper Blade: Service and Repair Wiper Blade Element Replacement WIPER BLADE ELEMENT REPLACEMENT REMOVAL PROCEDURE IMPORTANT: Replace the wiper blade element if it is removed from the wiper blade. 1. Remove the wiper blade from the wiper arm. 2. Remove the bottom claws (2) of the wiper blade (1) from the notches in the wiper blade element (3). 3. Pull the wiper blade element (3) out through the wiper blade claws (2). INSTALLATION PROCEDURE IMPORTANT: Keep the wiper blade claws in the rubber claw channel of the wiper blade element. Do not allow the claws of the wiper blade to contact the metal spline of the wiper blade element. 1. Insert the open end of the wiper blade element (3) into the bottom claws of the wiper blade (2). 2. Guide the wiper blade element (3) through the wiper blade (1) claw sets. 3. Engage the bottom claw (2) of the wiper blade (1) into the notches in wiper blade element (3). 4. Install the wiper blade onto the wiper arm. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair > Wiper Arm Blade Replacement > Page 11726 Wiper Blade: Service and Repair Blade Element Cleaning BLADE ELEMENT CLEANING Lift each blade assembly off of the windshield and clean the element with a cloth saturated with full strength washer solvent. Then rinse the blade assemblies with clear water. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Forward Of Windshield Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 11730 Windshield Wiper System Module Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 11731 Wiper Control Module: Service and Repair WIPER DRIVE SYSTEM MODULE REPLACEMENT TOOLS REQUIRED - J 39232 Wiper Transmission Separator - J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the air inlet grille panel. 2. Remove the wiper motor water deflector. 3. Using the J 39232 , disconnect the wiper transmission from the wiper motor crank arm to aid in the removal of the wiper drive system module. 4. Remove the wiper drive system module screws. 5. Disconnect the wiper motor electrical connector. 6. Remove the wiper drive system module from the vehicle. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations > Page 11732 1. Position the wiper drive system module to the vehicle. 2. Connect the wiper motor electrical connector. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the wiper drive system screws. Tighten Tighten the screws to 10 N.m (89 lb in). 4. Using the J 39529 , Install the wiper transmission to the wiper motor crank arm. 5. Install the wiper motor water deflector. 6. Install the air inlet grille panel. 7. Inspect the wipers for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Gear Box > Component Information > Service and Repair Wiper Gear Box: Service and Repair WIPER TRANSMISSION REPLACEMENT REMOVAL PROCEDURE 1. Remove the air inlet grille panel. 2. Remove the wiper drive system module. 3. Remove the wiper transmission caps. 4. Remove the wiper transmission screws. 5. Remove the wiper transmission from the wiper drive system module tube frame. INSTALLATION PROCEDURE 1. position the wiper transmission to the wiper drive system module tube frame. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install wiper transmission screws. Tighten Tighten the screws to 9 N.m (80 lb in). 3. Install the wiper transmission caps. 4. Install the wiper drive system module. 5. Install the air inlet grille panel. 6. Operate the windshield wipers and inspect for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement Wiper Motor: Service and Repair Wiper Motor Cover Replacement WIPER MOTOR COVER REPLACEMENT REMOVAL PROCEDURE 1. Remove the air inlet grille panel. 2. Remove the wiper drive system module. 3. Remove the wiper motor cover screws. 4. Remove the wiper motor cover from the wiper motor. INSTALLATION PROCEDURE 1. Position the wiper motor cover to the wiper motor. NOTE: Refer to Fastener Notice in Service Precautions. 2. Install the wiper motor cover screws. Tighten Tighten the screws to 2 N.m (18 lb in). 3. Install the wiper drive system module. 4. Install the air inlet grille panel. 5. Operate the windshield wipers and inspect for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 11740 Wiper Motor: Service and Repair Wiper Motor Replacement WIPER MOTOR REPLACEMENT REMOVAL PROCEDURE 1. Remove the air inlet grille panel. 2. Remove the wiper motor crank arm. 3. Remove the wiper drive system module. 4. Remove the wiper motor screws. 5. Remove the wiper motor from the wiper drive system module. 6. Remove the shaft seal and the water shield from the wiper motor. INSTALLATION PROCEDURE 1. Install the water shield and shaft seal onto the wiper motor. 2. Position the wiper motor to the wiper drive system module. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the wiper motor screws. Tighten Tighten the screws to 7 N.m (62 lb in). 4. Install the wiper drive system module. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 11741 5. Install the wiper motor crank arm. 6. Install the air inlet grille panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 11742 Wiper Motor: Service and Repair Wiper Motor Crank Arm Replacement WIPER MOTOR CRANK ARM REPLACEMENT TOOLS REQUIRED - J 39232 Wiper Transmission Separator - J 39529 Wiper Transmission Installer REMOVAL PROCEDURE 1. Remove the air inlet grille panel. 2. Remove the wiper motor water deflector. 3. Using the J 39232 , disconnect the wiper transmission from the wiper motor crank arm. 4. Remove the wiper motor crank arm cover. 5. Remove the wiper motor crank arm screw. 6. Remove the wiper motor crank arm from the wiper motor. INSTALLATION PROCEDURE Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 11743 1. Position the wiper motor crank arm onto the wiper motor. 2. Measure the gap between wiper motor crank arm and the bracket tab. If the gap is not 4-8 mm (0.157-0.314 in), remove the wiper motor crank arm and repeat installation. NOTE: Refer to Fastener Notice in Service Precautions. 3. Install the wiper motor crank arm screw. Tighten Tighten the screw to 16 N.m (12 lb ft). 4. Install the wiper motor crank arm cover. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 11744 5. Using the J 39529 , install the wiper transmission to the wiper motor crank arm. 6. Install the air inlet grille panel. 7. Install the wiper motor water deflector. 8. Operate the windshield wipers and inspect for proper operation. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair > Wiper Motor Cover Replacement > Page 11745 Wiper Motor: Service and Repair Wiper Motor Water Deflector Replacement WIPER MOTOR WATER DEFLECTOR REPLACEMENT TOOLS REQUIRED J 38778 Door Trim Pad and Garnish Clip Remover REMOVAL PROCEDURE 1. Remove the air inlet grille Panel. 2. Using the J 38778 , remove the wiper motor water deflector push-in retainer. 3. Remove the wiper motor water deflector from the wiper drive system module. INSTALLATION PROCEDURE 1. Position the wiper motor water deflector to the wiper drive system module. 2. Install the wiper motor water deflector push-in retainer. 3. Install the air inlet grille Panel. Chevrolet Impala Workshop Manual (V6-3.8L VIN K (2004)) Chevrolet Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Locations Wiper Switch: Locations Turn Signal/Multifunction Switch